Aerosol delivery device with segmented electric heater

Abstract

An aerosol delivery device is provided.SOLUTION: In various implementations, the aerosol delivery device comprises a control body having an exterior housing, an electrical energy source positioned within the housing, a control component operatively connected to the electrical energy source, a heating assembly operatively connected to the control component, and an aerosol source member comprising an aerosol generating component configured to be positioned proximate the heating assembly. The heating assembly comprises a series of heating members, each heating member being independent and separate and configured to heat a segment of the aerosol source member.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to aerosol delivery articles and their use for obtaining tobacco components or other materials in an inhalable form. The articles can be made from tobacco, derived from tobacco, or otherwise incorporate tobacco for human consumption. More specifically, the present disclosure provides aerosol delivery devices in which tobacco, tobacco-derived materials, or other materials are heated, preferably without significant combustion, to provide an inhalable substance in the form of a vapor or aerosol, in various embodiments. The present disclosure also relates to aerosol delivery devices including a reservoir and a vaporization assembly that can utilize electrical power to heat an aerosol precursor composition to generate an aerosol. [Background technology]

[0002] Many smoking articles have been proposed over the years as improvements or replacements for smoking products based on tobacco combustion. Exemplary replacements include devices in which a solid or liquid fuel is burned to transfer heat to the tobacco, or devices in which a chemical reaction is used to provide such a heat source. Examples include the smoking articles described in U.S. Patent No. 9,078,473 to Worm et al., the entire contents of which are incorporated herein by reference.

[0003] The gist of the improvement or replacement of smoking articles has typically been to provide the sensation associated with smoking cigarettes, cigars or pipes without delivering a significant amount of incomplete combustion and pyrolysis products.For this purpose, many smoking products, flavor generators and medicinal inhalers have been proposed, which utilize electrical energy to vaporize or heat volatile materials, or to provide the sensation of smoking cigarettes, cigars or pipes without significantly burning tobacco.For example, see the various alternative smoking articles, aerosol delivery devices and heat sources described in the background art of Robinson et al., U.S. Patent No. 7,726,320, and Griffith, Jr. et al., U.S. Patent Application Publication No. 2013 / 0255702 and Sears et al., U.S. Patent Application Publication No. 2014 / 0096781, which are incorporated herein by reference in their entirety. See also, for example, the various types of smoking articles, aerosol delivery devices, and electrically powered heating sources referenced by trade names and commercial sources described in U.S. Patent Application Publication No. 2015 / 0220232 to Bless et al., which is incorporated herein by reference in its entirety. Additional types of smoking articles, aerosol delivery devices, and electrically powered heating sources referenced by trade names and commercial sources are described in U.S. Patent Application Publication No. 2015 / 0245659 to DePiano et al., which is also incorporated herein by reference in its entirety.Other representative cigarettes or smoking articles that have been described, and in some cases are commercially available, include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al., U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,249,586 to Count ...249,586 to Counts et al., U.S. Pat. No. 5,249,586 to Counts et al., U.S. Pat. No. 5,249,586 to Counts et al., U.S. Pat. No. 5,249,586 to Counts et al., U.S U.S. Pat. No. 5,388,594 to Higgins et al., U.S. Pat. No. 5,666,977 to Adams et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,511 to Kobayashi, U.S. Pat. No. 3,253 to Robinson et al., U.S. Pat. No. 7,726,320 to Hamano, U.S. Pat. No. 7,896,006 to Shayan, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. App. Pub. Nos. 2009 / 0095311 to Hon, U.S. Pat. App. Pub. Nos. 2006 / 0196518 to Hon, U.S. Pat. App. Pub. Nos. 2009 / 0126745 and 2009 / 0188490 to Thorens et al. U.S. Patent Application Publication No. 2009 / 0272379, U.S. Patent Application Publication Nos. 2009 / 0260641 and 2009 / 0260642 to Monsees et al., U.S. Patent Application Publication Nos. 2008 / 0149118 and 2010 / 0024834 to Oglesby et al., U.S. Patent Application Publication No. 2010 / 0307518 to Wang, and WO 2010 / 091593 to Hon.

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

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

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

[0007] In various embodiments, the present disclosure provides an aerosol delivery device, including, but not limited to, the following exemplary embodiments:

[0008] Exemplary embodiment 1: An aerosol delivery device comprising: a control body having an external housing; an electrical energy source disposed within the housing; a control component operably connected to the electrical energy source; a heating assembly operably connected to the control component; and an aerosol source member including an aerosol generating component configured to be disposed near the heating assembly, wherein the heating assembly comprises a series of heating members, each heating member being independent and distinct and configured to heat a segment of the aerosol source member.

[0009] Exemplary embodiment 2: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the heating assembly comprises a movable jaw and a fixed jaw, a heating member disposed on the movable jaw, and the movable jaw is configured to move between an open position in which the movable jaw is spaced apart from the fixed jaw and the heating member is not in contact with the aerosol source member, and a closed position in which the series of heating members on the movable jaw are in contact with the aerosol source member.

[0010] Exemplary embodiment 3: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, further comprising a receiving sleeve configured to receive an aerosol source member, the receiving sleeve being disposed between the movable jaw and the fixed jaw in the closed position.

[0011] Exemplary embodiment 4: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the series of heating members comprises a series of heating pins configured to penetrate the aerosol source member in the closed position and to create electrical connections with a series of corresponding connectors disposed on the fixed jaw.

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

[0013] Exemplary embodiment 6: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the series of heating members comprises individual heating elements configured to extend into the aerosol source member in the closed position.

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

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

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

[0017] Exemplary embodiment 10: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the series of heating members comprises a series of individual heating elements, the heating assembly comprises two or more movable jaws, one or more of the heating members is disposed on each movable jaw, and the movable jaws are configured to move between an open position in which the movable jaws are spaced apart from one another and the heating members are not in contact with the aerosol source member, and a closed position in which the series of heating elements of each movable jaw are in contact with the aerosol source member.

[0018] Exemplary embodiment 11: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the heating assembly includes three movable jaws, and the heating elements of each movable jaw have a staggered configuration relative to the other movable jaws.

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

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

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

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

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

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

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

[0026] Exemplary embodiment 19: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, configured such that each of the fixed heating elements is positioned proximate to a corresponding nebulizer chamber.

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

[0028] These and other features, aspects and advantages of the present disclosure will become apparent from the following detailed description taken in conjunction with the accompanying drawings, which are briefly described below.

[0029] To aid in understanding embodiments of the present disclosure, reference will now be made to the accompanying drawings, in which like reference numerals refer to like elements and in which the drawings are not necessarily drawn to scale. The drawings are merely examples and are not to be construed as limiting the present disclosure. [Brief explanation of the drawings]

[0030] [Figure 1] 1 shows a perspective schematic view of an aerosol delivery device according to an exemplary embodiment of the present disclosure. [Figure 2] 1 shows a schematic front view of an aerosol delivery device according to an exemplary embodiment of the present disclosure. [Figure 3] 1 shows a perspective view of certain components of a heating assembly of an aerosol delivery device, according to an exemplary embodiment of the present disclosure. [Figure 4] 1 shows a perspective view of certain components of a heating assembly and an aerosol source member of an aerosol delivery device according to an exemplary embodiment of the present disclosure. [Figure 5] 1 shows a perspective view of components of a heating assembly of an aerosol delivery device according to an exemplary embodiment of the present disclosure. [Figure 6] 1A-1D show top and perspective views of certain components of a heating assembly of an aerosol delivery device in an open position, according to an exemplary embodiment of the present disclosure. [Figure 7] 1A-1C show bottom views of certain components of a heating assembly of an aerosol source member shown in open and closed positions according to exemplary embodiments of the present disclosure. [Figure 8] 1 shows a perspective view of an aerosol delivery device according to an exemplary embodiment of the present disclosure. [Figure 9] 1 shows a perspective exploded view of an aerosol delivery device according to an exemplary embodiment of the present disclosure. [Figure 10] 1 shows a perspective view of an aerosol source member according to an exemplary embodiment of the present disclosure. [Figure 11] 1 shows a perspective exploded view of an aerosol source member according to an exemplary embodiment of the present disclosure. [Figure 12]1 shows a perspective view of a cartridge of an aerosol source member according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0031] The present disclosure is described more fully below. However, 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 embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. It should be noted that as used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0032] The present disclosure provides articles that use electrical energy to heat a material (preferably without significantly burning the material) to form an inhalable substance, and the articles are small enough to be considered "handheld" devices. In certain embodiments, the articles can be specifically characterized as smoking articles. As used herein, this term is intended to mean an article that provides the taste and / or sensation (e.g., feel or mouthfeel) of smoking a cigarette, cigar, or pipe without actually burning any components of the article. The term smoking article does not necessarily indicate that the article produces smoke, in the sense of a combustion or pyrolysis by-product, during operation. Rather, smoking relates to the physical actions of an individual in using the article, e.g., holding the article in one's hand, drawing on one end of the article, and inhaling from the article. In further embodiments, the articles of the present invention can be characterized as vapor-producing articles, aerosolizing articles, or pharmaceutical delivery articles. Thus, the articles can be configured to provide one or more substances in an inhalable state. In some embodiments, the inhalable substance can be substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). In other embodiments, the inhalable substance can be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). The physical form of the inhalable substance is not necessarily limited by the nature of the article of the present invention, but can depend on the nature of the medium and the inhalable substance itself, with respect to whether it exists in a vapor state or an aerosol state. In some embodiments, the terms "vapor" and "aerosol" can be interchangeable. Thus, for simplicity, the terms "vapor" and "aerosol" used to describe this disclosure will be understood to be interchangeable unless otherwise specified.

[0033] Although the systems are generally described herein with respect to embodiments relating to aerosol delivery devices, such as so-called "electronic cigarettes" or "tobacco heating products," it should be understood that the features, components, features, and methods may be embodied in many different forms and associated with a variety of items. For example, the descriptions provided herein can be used in combination with traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heated tobacco products, and related packaging embodiments for any of the products disclosed herein. Accordingly, it should be understood that the descriptions of the features, components, features, and methods disclosed herein are discussed by way of example only with respect to embodiments relating to aerosol delivery devices, and can be embodied in and used in a variety of other products and methods.

[0034] The aerosol delivery device of the present disclosure can also be characterized as a vapor product or drug delivery article. Accordingly, such an article or device can be configured to provide one or more substances (e.g., flavors and / or active pharmaceutical ingredients) in an inhalable form or state. For example, the inhalable substance can be substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance can be in aerosol form (i.e., a suspension of fine solid particles or liquid droplets in a gas). For clarity, the term "aerosol" as used herein is meant to include vapors, gases, and aerosols in any form or type suitable for human inhalation, whether or not they are visible and whether or not they are in a form that can be considered smoky.

[0035] In use, the aerosol delivery device of the present disclosure can undergo many of the physical actions used by an individual when using a traditional type of smoking article (e.g., a cigarette, cigar, or pipe used by lighting tobacco and inhaling.) For example, a user of the aerosol delivery device of the present disclosure can hold the article like a traditional type of smoking article, draw on one end of the article to inhale the aerosol produced by the article, take puffs at selected time intervals, etc.

[0036] The aerosol delivery device of the present disclosure generally includes a number of components disposed within an outer shell or body. The overall design of the outer shell or body can be similar, and the type or configuration of the outer body can vary, which can define the overall dimensions and shape of the aerosol delivery device. In some examples, an elongated body resembling the shape of a cigarette or cigar can be formed from a single, integral shell, or the elongated body can be formed from two or more separable parts. For example, the aerosol delivery device can include an elongated shell or body that can be substantially tubular in shape and can resemble the shape of a traditional cigarette or cigar. In other embodiments, various other shapes and configurations can be used (e.g., rectangular or fob-shaped).

[0037] In one embodiment, all components of the aerosol delivery device are housed within a single outer body or shell. Alternatively, the aerosol delivery device can have two or more shells that are joined and separable. For example, the aerosol delivery device can have a control body including a shell that houses one or more reusable components (e.g., a rechargeable battery and various electronics for controlling the operation of the item) and a disposable portion (e.g., a disposable cartridge or aerosol source member that houses aerosol precursor materials, flavorings, etc.) removably attached thereto.

[0038] In general, the aerosol delivery devices of the present disclosure may generally comprise some combination of an aerosol source member, including an electrical energy source (i.e., a power source), at least one control component (e.g., a means for activating, controlling, regulating, and terminating power for heat generation, such as by controlling the flow of current from the electrical energy source to other components of the device, e.g., a microprocessor, either separately or as part of a microcontroller), a heating element or heat-generating component (e.g., an electrically conductive, resistive heating element or an induction heating element), and an aerosol-generating component that can be positioned in proximity to or in direct contact with the heating element. When the heating element heats the aerosol-generating component, an inhalable substance is formed, released, or generated from the aerosol-generating component in a physical form suitable for inhalation by a consumer. It should be noted that the foregoing terms mean that references to release, releasing, releases, or released can be interpreted to include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol, or a mixture thereof. It should be noted that the foregoing terms mean that references to release, releasing, releases, or released can be interchanged to include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol, or a mixture thereof, and such terms are also used interchangeably herein unless otherwise specified.

[0039] As described above, the aerosol delivery device may incorporate a source of electrical energy (e.g., a battery and / or other power source, e.g., a capacitor) to provide a flow of electrical current sufficient to provide various functions for the aerosol delivery device, such as powering the heating element, powering the control system, powering the indicators, etc. The power source can take on a variety of embodiments. Preferably, the power source provides sufficient power to rapidly heat the heating element to form an aerosol and power the aerosol delivery device throughout use for a desired duration. The power source is preferably sized to fit conveniently within the aerosol delivery device so that the aerosol delivery device can be easily handled. Furthermore, preferred power sources are lightweight enough so as not to detract from the desired smoking experience.

[0040] More specific types, configurations, and arrangements of components within a single-shell unit or a multi-part separable-shell unit of the aerosol delivery device of the present disclosure will become apparent in light of the further disclosure provided herein. Furthermore, the selection of various aerosol delivery device components can be understood by considering commercially available electronic aerosol delivery devices. Furthermore, the arrangement of components within an aerosol delivery device can be understood by considering commercially available electronic aerosol delivery devices. Examples of commercially available products whose components, methods of operation, materials contained therein, and / or other attributes thereof can be included in the device of the present disclosure, as well as manufacturers, designers, and / or assignees of components and related technology usable in the aerosol delivery device of the present disclosure, are described in U.S. Patent Application No. 15 / 222,615, filed July 28, 2016, to Watson et al., which is incorporated herein by reference in its entirety.

[0041] Although devices according to the present disclosure may take on various embodiments, as described in detail below, consumer use of the devices will be similar in scope. In particular, the device may be provided as multiple components that are assembled by the consumer for use and then disassembled by the consumer. Specifically, the consumer may have a reusable control body that is generally cylindrical, generally rectangular, generally cuboid, or another shape with an opening disposed in a portion of the control body housing. In some embodiments, the housing may also include one or more indicators of active use of the device (e.g., one or more indicator lights, indicia displayed on an electronic display, tactile feedback, some combination thereof, etc.). In some embodiments, one or more aerosol source members are engageable with or receivable by the openings in the control body. To use the item, the consumer may insert the aerosol source member into the opening or otherwise assemble the aerosol source member and control body such that the device is operable as described herein. In some embodiments, the aerosol source member can be inserted into the control body as permitted by the overall structure of the components and / or other internal receiving features. In some instances, at least a portion of the aerosol source member at least large enough to be inserted into a consumer's mouth for smoking therewith remains outside the control body. This can be referred to as the mouth end of the aerosol source member. In other instances, a portion of the aerosol delivery device itself can be at least large enough to be inserted into a consumer's mouth. This can be referred to as the mouth end of the aerosol delivery device.

[0042] During use, a consumer initiates heating of a heating element adjacent to the aerosol-generating component (or a particular portion thereof) of the aerosol source member, and heating of the component releases inhalable material into a space within the housing and / or aerosol source member to generate the inhalable material. When the consumer inhales into the mouth end of the aerosol source member or the mouth end of the aerosol delivery device, air is drawn into and / or through the aerosol source member (e.g., through an opening in the aerosol delivery device and / or through the aerosol source member itself). As the drawn-in material exits the mouth end of the aerosol source member or the mouth end of the aerosol delivery device and enters the consumer's mouth, the combination of the drawn-in air and the released inhalable material is inhaled by the consumer. In some embodiments, to initiate heating, the consumer may manually activate a push button or similar component that causes the heating element to receive electrical energy from a battery or other power source. The electrical energy can be supplied for a predetermined length of time or can be manually controlled. Preferably, the flow of electrical energy does not continue substantially between puffs using the device (although the energy flow may continue to maintain a baseline temperature above ambient temperature, e.g., a temperature that facilitates rapid heating to an actuation heating temperature). In other embodiments, heating can be initiated by the consumer's puff action through the use of various sensors, as described elsewhere herein. Heating may cease or be reduced when a puff is discontinued. Once the consumer has taken a sufficient number of puffs to emit a sufficient amount of inhalable substance (e.g., an amount sufficient to represent a typical smoking experience), the aerosol source member can be detached from the control body and discarded.

[0043] FIG. 1 shows a perspective view of an aerosol delivery device 100 according to an exemplary embodiment of the present disclosure. In particular, FIG. 1 shows the aerosol delivery device 100 including a housing 102 and an aerosol source member 104. FIG. 2 shows a front view of the aerosol delivery device 100, with portions of the housing 102 removed to reveal some internal components. In particular, the aerosol delivery device 100 of the illustrated embodiment further includes an electrical energy source 106 (e.g., a battery, which may be rechargeable, and / or a rechargeable supercapacitor), a control component 108 (e.g., a microprocessor, either separately or as part of a microcontroller, a printed circuit board (PCB) including a microprocessor and / or a microcontroller, etc.), and a heating assembly 110. As described in further detail below, the heating assembly 110 of various embodiments comprises a series of independent and separate heating elements, each configured to heat a segment of the aerosol source member 104.

[0044] In various embodiments, one or both of the control component 108 and the electrical energy source 106 can be coupled with the housing 102. For purposes of this application, the phrase "coupled" when used with respect to one component with respect to another component may encompass embodiments in which one component is disposed within another component and / or embodiments in which one component is separate but otherwise operably connected to another component. For example, in the illustrated embodiment, both the control component 108 and the electrical energy source 106 are disposed within the housing 102. However, in other embodiments, one or both of the control component 108 and the electrical energy source 106 can be separate components. Additional information regarding the control component 108 and the electrical energy source 106 is provided below.

[0045] In some embodiments, the housing 102 may also include one or more push buttons configured to activate certain operations of the device 100, such as, for example, turning on the device and initiating heating of the heating assembly 110 (e.g., one or more heating elements of the heating assembly). As described in further detail below, in various embodiments, the aerosol source member 104 may include a heated end configured to be inserted into the housing 102 and a mouth end through which a user inhales to generate aerosol. Note that while the aerosol delivery device 100 in FIG. 1 is shown as having a generally rectangular or fob-shaped housing 102 for ease of illustration, in other embodiments, the housing 102 is generally tubular in shape and, therefore, can have any other shape, including an elongated shell or body, such as one resembling the shape of a traditional cigarette or cigar; thus, the components described below can be sized and configured to fit inside the elongated body.

[0046] In certain embodiments, one or both of the housing 102 and the aerosol source member 104 can be referred to as disposable or reusable. For example, the electrical energy source 106 may comprise a replaceable or rechargeable battery, a solid-state battery, a thin-film solid-state battery, a rechargeable supercapacitor, or the like, and thus may be combined with any type of charging technology, including connection to a wall charger, a connection to an automobile charger (i.e., cigarette lighter socket), a connection to a computer via a Universal Serial Bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), or the like, a photovoltaic cell (sometimes called a solar cell) or solar panel, a wireless charger such as a charger using inductive wireless charging (e.g., including wireless charging compliant with the Qi wireless charging standard by the Wireless Power Consortium (WPC)), or a radio frequency (RF)-based charger. An example of an inductive wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is incorporated herein by reference in its entirety. Additionally, in some embodiments, the aerosol source member 104 may comprise a disposable device. Disposable components for use with the control body are disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0047] In various embodiments, control component 108 may comprise a control circuit (which may be connected to additional components as further described herein) connectable to electrical energy source 106 by conductive wires. In various embodiments, control component 108 may control when and how heating assembly 110 (e.g., one or more heating elements of the heating assembly) receives electrical energy to heat the aerosol-generating components of aerosol source member 104 to release an inhalable substance for inhalation by the consumer. Such control may relate to the actuation of a pressure-sensitive switch, or the like, described in further detail below. Note that the terms “connected” or “coupled” should not be interpreted as requiring a direct connection without intervening components. Rather, these terms may encompass a direct connection and / or a connection via one or more intervening components. Thus, in various embodiments, these terms will be understood to mean operatively connected or operatively coupled. In various embodiments, the control component of the present disclosure may comprise the control components and methods described in U.S. Patent Application No. 15 / 976,526, filed May 10, 2018, entitled "Control Component for Segmented Heating in an Aerosol Delivery Device," which is incorporated herein by reference in its entirety.

[0048] In some embodiments, the control component 108 can be configured to precisely control the amount of heat provided to the aerosol-generating component. While the heat required to volatilize a sufficient volume of aerosol-forming substance to provide the desired dose of inhalable substance per puff can vary for each particular substance used, it can be particularly useful to heat the heating assembly to a temperature of at least 120°C, at least 130°C, or at least 140°C. In some embodiments, the heating temperature can be at least 150°C, at least 200°C, at least 300°C, or at least 350°C to volatilize an adequate amount of aerosol-forming substance and thus provide the desired dose of inhalable substance. However, it may be particularly desirable to avoid heating to temperatures substantially above about 550°C to avoid degradation and / or excessive premature volatilization of the aerosol-forming substance. Note that in some embodiments, the heating process may include various stages. For example, some embodiments may include a preheating stage in which the heating assembly (e.g., each of the individual heating elements) can be heated to about 100°C. Then, upon activation of any individual heater (e.g., by a push button, etc.), the temperature of that particular heater can be increased as described above. In particular, heating should be at a temperature low enough and for a period of time short enough to avoid significant combustion (preferably any combustion) of the aerosol-generating components. The present disclosure can provide components of the present articles in combinations and modes of use that produce a desired amount of inhalable substance at relatively low temperatures, among other things. Thus, yield can refer to one or both of aerosol generation within the article and delivery from the article to the consumer. In certain embodiments, the heating temperature can be from about 120°C to about 300°C, from about 130°C to about 290°C, from about 140°C to about 280°C, from about 150°C to about 250°C, or from about 160°C to about 200°C. As described in more detail below, the duration of heating can be controlled by several factors.As described further herein, the heating temperature and duration may depend on the desired volume of aerosol and ambient air desired to be drawn through the aerosol source member. However, the duration may vary depending on the heating rate of the heating assembly, as the article may be configured so that the heating element is energized only until the desired temperature is reached. Alternatively, the duration of heating may be tied to the duration of a puff by the consumer using the article. Generally, the temperature and duration of heating are controlled by one or more components housed in the control body, as described above.

[0049] The amount of inhalable material emitted by the aerosol source member can vary based on the nature of the aerosol-generating components. Preferably, the aerosol source member is configured with sufficient amounts of aerosol-generating components, along with sufficient amounts of any aerosol-forming agents, to function at a sufficient temperature for a sufficient time to emit the desired amount over the course of use. The amount may be provided in a single inhalation from the aerosol source member, or may be divided into several puffs from the article over a relatively short period of time (e.g., less than 30 minutes, less than 20 minutes, less than 15 minutes, less than 10 minutes, or less than 5 minutes). For example, the device may provide an amount of nicotine of about 0.01 mg to about 0.1 mg, about 0.05 mg to about 1.0 mg, about 0.08 mg to about 0.5 mg, about 0.1 mg to about 0.3 mg, or about 0.15 mg to about 0.25 mg per puff with the aerosol source member. In other embodiments, the desired amount can be characterized in terms of the amount of wet total particulate matter delivered based on the duration and volume of the puff. For example, the aerosol source member may deliver at least 1.0 mg of wet total particulate matter per puff when smoked under standard FTC smoking conditions of a 2-second, 35 ml puff for a specified number of puffs (as described elsewhere herein). Such testing may be performed using any standard smoking machine. In other embodiments, the amount of total particulate matter (TPM) produced under the same conditions for each puff may be at least 1.5 mg, at least 1.7 mg, at least 2.0 mg, at least 2.5 mg, at least 3.0 mg, between about 1.0 mg and about 5.0 mg, between about 1.5 mg and about 4.0 mg, between about 2.0 mg and about 4.0 mg, or between about 2.0 mg and about 3.0 mg, at least 3 mg to about 7 mg, between about 4 mg and about 8 mg, and between about 5 mg and about 10 mg.

[0050] As mentioned above, the aerosol delivery device 100 of some embodiments may include a push button that can be coupled to a control component for manual control of the heating element. For example, in some embodiments, a consumer may energize the heating assembly 110 using a push button. Similar functionality associated with a push button may be achieved by other mechanical or non-mechanical means (e.g., magnetic or electromagnetic). Thus, activation of the heating assembly 110 can be controlled by a single push button. Alternatively, multiple push buttons may be provided to separately control various operations. In some embodiments, the one or more push buttons present may be located substantially flush with the casing of the housing 102.

[0051] Instead of (or in addition to) any push button, the aerosol delivery device 100 of the present disclosure may include a component that energizes the heating assembly 110 in response to a consumer drawing on an article (i.e., puff-activated heating). For example, the device may include a switch or flow sensor (not shown) within the housing 102 that is sensitive to either pressure or airflow changes when a consumer draws on an article (i.e., puff-activated switch). Other suitable current activation / deactivation mechanisms may include a temperature-activated on / off switch or a lip-pressure-activated switch, or a touch sensor (e.g., a capacitance-based touch sensor) configured to sense contact between a user (e.g., the user's mouth or finger) and one or more surfaces of the aerosol delivery device 100. An exemplary mechanism capable of providing such puff-activation capability includes the Model 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc. of Freeport, Illinois. Using such a sensor, changes in pressure when a consumer draws on the device can rapidly activate the heating element. Additionally, a flow-sensing device, such as one that uses the principles of hot wire anemometry, may be used to energize the heating assembly sufficiently quickly after sensing a change in airflow. Another pneumatically actuated switch that can be used is a pressure differential switch, such as model number MPL-502-V, range A, manufactured by Micro Pneumatic Logic, Inc., Fort Lauderdale, Florida. Another suitable pneumatically actuated mechanism is a pressure-sensitive transducer (e.g., with an amplifier or gain stage) coupled to a comparator for detecting a predetermined threshold pressure. Yet another suitable pneumatically actuated mechanism is a vane deflected by the airflow, the movement of which is detected by a motion-sensing means. Yet another suitable actuation mechanism is a piezoelectric switch. Also useful is a suitably connected Honeywell MicroSwitch Microbridge Airflow Sensor, part number AWM 2100V, manufactured by the MicroSwitch Division of Honeywell, Inc., Freeport, Illinois.Additional examples of demand-operated electrical switches that can be used in heating circuits according to the present disclosure are described in U.S. Pat. No. 4,735,217 to Gerth et al., which is incorporated herein by reference in its entirety. Other suitable differential switches, analog pressure sensors, flow sensors, and the like will be apparent to those skilled in the art with the knowledge of this disclosure. In some embodiments, the housing 102 may include a pressure-sensing tube or other passageway that provides a fluid connection between the puff-activated switch and the aerosol source member 104 so that pressure changes during inhalation can be easily identified by the switch. Other exemplary smoke actuators useful in accordance with the present disclosure are disclosed in U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,874 to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., and U.S. Patent No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entireties. Reference is also made to the control scheme described in U.S. Patent No. 9,423,152 to Ampolini et al., which is incorporated herein by reference in its entirety.

[0052] In some embodiments, when a consumer draws on the mouth end of the aerosol source member 104, the current actuation means can rapidly generate heat by ensuring that the flow of current through the heating assembly is unrestricted or uninterrupted. For rapid heating, it can be useful to include a current regulation component to (i) regulate the flow of current through the heating assembly to control heating of the heating assembly and the resulting temperature, and (ii) prevent overheating and degradation of the aerosol generation components. In some embodiments, the current regulation circuitry can be time-based. Specifically, such a circuitry can include a means for ensuring that the flow of current through the heating element is uninterrupted for an initial period during inhalation, followed by a timer means for regulating the current flow until inhalation is complete. For example, subsequent regulation can include rapid on / off switching of the current flow (e.g., on the order of about every 1-50 milliseconds) to maintain the heating assembly (or one or more heating elements of the heating assembly) within a desired temperature range. Furthermore, regulation can comprise simply ensuring that the current flow is uninterrupted until the desired temperature is achieved, and then completely turning off the current flow. The heating assembly (or one or more heating elements of the heating assembly) may be reactivated by the consumer initiating another puff on the article (or by manually activating a push button, depending on the particular switch embodiment used to activate the heater). Alternatively, subsequent adjustments may include modulating the flow of current through the heating assembly (or one or more heating elements of the heating assembly) to maintain the heating assembly (or one or more heating elements of the heating assembly) within a desired temperature range. In some embodiments, the heating assembly (or one or more heating elements of the heating assembly) may be energized for a duration of about 0.2 seconds to about 5.0 seconds, about 0.3 seconds to about 4.0 seconds, about 0.4 seconds to about 3.0 seconds, about 0.5 seconds to about 2.0 seconds, or about 0.6 seconds to about 1.5 seconds to emit a desired dose of inhalable substance. One exemplary time-based current regulation circuit may include a transistor, a timer, a comparator, and a capacitor.Suitable transistors, timers, comparators, and capacitors are commercially available and will be apparent to those skilled in the art. Exemplary timers are those available from NEC Electronics as C-1555C and from General Electric Intersil, Inc. as ICM7555, as well as so-called "555 timers" in various sizes and configurations. An exemplary comparator is available from National Semiconductor as LM311. Additional description of such time-based current regulation circuits is provided in U.S. Patent No. 4,947,874 to Brooks et al., which is incorporated herein by reference in its entirety.

[0053] In light of the above, it can be appreciated that various mechanisms can be used to facilitate activation / deactivation of current to the heating assembly (or one or more components of the heating assembly). For example, the device may include a timer for regulating the flow of current through the article (such as during inhalation by the consumer). The device may further include a timer-responsive switch for enabling and disabling the flow of current to the heating element. Regulating the current can also comprise the use of a capacitor and components for charging and discharging the capacitor at a prescribed rate (e.g., a rate approximating the rate at which the heating element heats and cools). The current may be regulated so that the current through the heating element is uninterrupted, particularly for an initial period during inhalation, but the current may be turned off or cycled alternately on and off after the initial period until inhalation is completed. Such cycles can be controlled by a timer capable of generating preset switching cycles, as described above. In certain embodiments, the timer can generate a periodic digital waveform. The flow during the initial period can be further regulated by using a comparator that compares a first voltage at the first input with a threshold voltage at the threshold input and generates an output signal when the first voltage equals the threshold voltage, thereby enabling the timer. Such an embodiment can further include a component for generating a threshold voltage at the threshold input and a component for generating the threshold voltage at the first input upon the elapse of the initial period.

[0054] Additional components are available for the aerosol delivery devices of the present disclosure. For example, U.S. Pat. No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouth end of a device that detects a user's lip movements associated with drawing and subsequently causes heating of the heating device; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow to a heat load array in response to a drop in pressure through a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. discloses a receptacle within a smoking device that includes an identifier that detects non-uniformities in infrared transparency of an inserted component and a controller that executes a detection routine when a component is inserted into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer et al. describes predefined executable power cycles having multiple differential phases; and U.S. Pat. No. 5,934,289 to Watkins et al. describes a photonic oscillator. No. 5,954,979 to Counts et al. discloses a means for varying the resistance to draw through a smoking device; U.S. Pat. No. 6,803,545 to Blake et al. discloses particular battery configurations for use in smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses a computer interface means for a smoking device to facilitate charging and enable computer control of the device; U.S. Pat. No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device; and PCT Patent Application WO 2010 / 003480 to Flick discloses a fluid flow sensing system to indicate a puff using an aerosol generating system, all of the foregoing disclosures are incorporated herein by reference in their entireties. Another method uses electrical resistance changes to actuate the aerosol delivery device and / or its heating assembly.It works by using a very thin, small metal probe in the form of a strip or wire that is attached perpendicular to the airflow within the cartridge. The airflow generated by the user exerts a mechanical force on the probe, bending it to some degree. This change in shape, which causes bending / tension on a portion of the probe, creates a change in the electrical resistance of the probe, and this change in resistance is sent as a pulse / information to the PCB, which acts as a trigger to activate the heating assembly 110.

[0055] Additional examples of components related to electronic aerosol delivery articles and disclosed materials or components that can be used in the present article include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513,253 to Kobayashi, U.S. Pat. No. 7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. No. 8,155,515 to Hon, and U.S. Pat. No. 6,155,515 to Hon. Nos. 6,944 and 8,375,957 to Thorens et al., U.S. Pat. No. 8,794,231 to Thorens et al., U.S. Pat. No. 8,851,083 to Oglesby et al., U.S. Pat. Nos. 8,915,254 and 8,925,555 to Monsees et al., U.S. Pat. No. 9,220,302 to DePiano et al., U.S. Patent Application Publication No. 2006 / 0196518 to Hon, and U.S. Pat. Examples of such aerosol delivery devices include U.S. Patent Application Publication No. 2009 / 0188490 to Oglesby et al., U.S. Patent Application Publication No. 2010 / 0024834 to Wang, U.S. Patent Application Publication No. 2010 / 0307518 to Wang, PCT Patent Application Publication No. WO 2010 / 091593 to Hon, and PCT Patent Application Publication No. WO 2013 / 089551 to Foo, each of which is incorporated herein by reference in its entirety. Furthermore, U.S. Patent Application No. 14 / 881,392 to Worm et al., filed October 13, 2015, discloses a capsule that can be included in an aerosol delivery device and a fob-shaped configuration for the aerosol delivery device, and is incorporated herein by reference in its entirety. In various embodiments, various materials disclosed by the aforementioned documents may be incorporated into the device, and all of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0056] As noted above, the electrical energy source 106 used to power the various electrical components of the device 100 may take on a variety of embodiments. Preferably, the electrical energy source provides sufficient energy to rapidly heat the heating assembly in the manner described above and can power the device through use with multiple aerosol source members 104 while still fitting conveniently into the device 100. Examples of useful electrical energy sources include lithium-ion batteries, preferably rechargeable (e.g., rechargeable lithium manganese dioxide batteries). In particular, lithium polymer batteries can be used because such batteries can improve safety. Other types of batteries, such as nickel-cadmium batteries, lithium-metal batteries, lithium-sulfur batteries, lithium-air batteries, nanowire batteries, graphene batteries, and foam batteries, can also be used. Furthermore, preferred electrical energy sources are lightweight enough so as not to detract from the desired smoking experience. Some examples of possible electrical energy sources are described in U.S. Pat. No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191 to Sur et al., filed October 21, 2015, the entire disclosures of each of which are incorporated herein by reference.

[0057] One example of an electrical energy source is the TKI-1550 rechargeable lithium-ion battery manufactured by Tadiran Batteries GmbH of Germany. In another embodiment, a useful electrical energy source may be an N50-AAA CADNICA nickel-cadmium battery manufactured by Sanyo Electric Company, Ltd. of Japan. In other embodiments, multiple such batteries, each providing 1.2 volts, may be connected in series. Other electrical energy sources, such as rechargeable lithium manganese dioxide batteries, may also be used. While any of these batteries or combinations thereof can be used for the electrical energy source, rechargeable batteries are preferred due to the cost and disposal considerations associated with disposable batteries. In embodiments in which a rechargeable battery is used, the aerosol delivery device 100 may further include charging contacts that interact with corresponding contacts in a standard 120-volt AC wall outlet or a conventional charging unit (not shown) that obtains power from another source, such as a vehicle's electrical system or a separate portable power source. In further embodiments, the electrical energy source may also include a capacitor. Capacitors can discharge faster than batteries and can be charged between puffs, allowing the capacitor to discharge at a slower rate than if a battery were used to directly power the heating element. For example, a supercapacitor, such as an electric double layer capacitor (EDLC), may be used separately from or in combination with a battery. If used alone, the supercapacitor may be charged before each use of the device 100. Thus, the present disclosure may also include a charger component attachable to the device between uses to replenish the supercapacitor. In certain embodiments of the present disclosure, a thin-film battery may be used.

[0058] As noted above, in various embodiments, the aerosol delivery device 100 may include one or more indicators (not shown). In various embodiments, the one or more indicators may be located anywhere on the housing 102. In some embodiments, the indicators may be lights (e.g., light-emitting diodes) that can provide indications of multiple aspects of the device's use. For example, a series of lights may correspond to the number of puffs taken on a given aerosol source member. Specifically, the lights may be illuminated sequentially with each puff, such that when all lights are illuminated, the consumer is notified that the aerosol source member has been consumed. Alternatively, all lights may be illuminated when the aerosol source member is inserted into the housing, and the lights may be turned off with each puff, such that when all lights are turned off, the consumer is notified that the aerosol source member has been consumed. In other embodiments, a series of lights may correspond to a series of heating elements, such that when one or more of the heating elements are activated, a corresponding light may be illuminated. In still other embodiments, there may be only a single indicator, the illumination of which may indicate that current is flowing through the heating assembly and that the device is actively heating. This may prevent a consumer from unintentionally leaving the device in active heating mode. In alternative embodiments, one or more of the indicators may be components of the aerosol source member. While the indicators are described above in connection with visual indicators of an on / off method, other indicators of operation are also encompassed. For example, visual indicators may also include changes in light color or intensity to indicate the progression of the smoking experience. Tactile and audible indicators are also encompassed by the present disclosure. Furthermore, combinations of such indicators may be used in a single device.

[0059] In various embodiments, the housing 102 can be formed from any material suitable for forming and maintaining a suitable structure, such as a tubular or rectangular shape, and for retaining the aerosol source member therein. In some embodiments, the housing may be formed from a single wall or multiple walls and from one or more materials (natural or synthetic) that are heat-resistant so as to maintain its structural integrity (e.g., not deteriorate) at least at temperatures that are the heating temperatures provided by the electric heating element, as further described herein. In some embodiments, heat-resistant polymers can be used. In other embodiments, ceramic materials can be used. In further embodiments, insulating materials can be used to prevent unnecessary heat transfer from the aerosol source element. When formed from a single layer, the housing may preferably have a thickness of about 0.2 mm to about 5.0 mm, about 0.5 mm to about 4.0 mm, about 0.5 mm to about 3.0 mm, or about 1.0 mm to about 3.0 mm. Additional exemplary types of components and materials that can be used to provide the above functionality or that can be used as substitutes for the above materials and components can be of the type described in U.S. Patent Application Publication No. 2010 / 00186757 to Crooks et al., U.S. Patent Application Publication No. 2010 / 00186757 to Crooks et al., and U.S. Patent Application Publication No. 2011 / 0041861 to Sebastian et al., the entire disclosures of which are incorporated herein by reference.

[0060] 3 shows a perspective view of certain components of the heating assembly 110 of the aerosol delivery device 100 of FIGS. 1 and 2 according to an exemplary embodiment of the present disclosure, and FIG. 4 shows a perspective view of certain components of the heating assembly 110 with the aerosol source member 104 disposed in the receiving sleeve 116 according to an exemplary embodiment of the present disclosure. In particular, the heating assembly 110 of the illustrated embodiment includes a movable jaw 112, a fixed jaw 114 (which are rotated upside down in the drawings for clarity of illustration), and a receiving sleeve 116. In the illustrated embodiment, the movable jaw 112, the fixed jaw 114, and / or the receiving sleeve 116 can be made from a metallic material (e.g., aluminum, stainless steel, a metal alloy, etc.), a ceramic material (e.g., alumina, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, etc.), a polymer (e.g., polyimide, thermoplastic polyimide, polybenzimidazole, polyetheretherketone, polypropylene, high-density polyethylene, etc.), a composite material, and / or any combination thereof, although other materials are possible. As described in more detail below, the movable jaw 112 in the illustrated embodiment is configured to move between an open position in which the movable jaw 112 is spaced apart from the fixed jaw 114 and the receiving sleeve 116, and a closed position in which the movable jaw 112 is adjacent to the fixed jaw 114 and the receiving sleeve 116 is located between the movable jaw 112 and the fixed jaw 114. In the illustrated embodiment, the receiving sleeve 116 has a generally cylindrical shape configured to receive at least the heated end of the aerosol source member 104. However, in other embodiments, the receiving sleeve may have any other shape, such as any shape that complements the shape of the heated end of the aerosol source member. In the illustrated embodiment, the movable jaw 112 and the fixed jaw 114 each have an interior shape configured to substantially surround the receiving sleeve 116, and thus at least the heated end of the aerosol source member 104. In particular, the inner surface 118 of the movable jaw 112 and the inner surface 119 of the fixed jaw 114 together form a shape that complements the shape of the receiving sleeve 116. Thus, when the movable jaw 112 is in the closed position, the inner surfaces 118, 119 together surround the receiving sleeve 116.

[0061] The movable jaw 112 in the illustrated embodiment includes a series of heating pins 120 extending outward from its inner surface 118. The movable jaw 112 in the illustrated embodiment also includes a pair of locating pins 122 extending outward from the inner surface 118 of the movable jaw 112. Note that in some embodiments, the locating pins 122 need not be present, as the heating pins can also serve this function. In various embodiments, the series of heating pins 120 are configured to electrically connect (in the closed position) with a series of corresponding connectors 124 disposed on the inner surface 119 of the fixed jaw 114. Additionally, the receiving sleeve 116 includes two opposing rows of openings 126 that align with the series of heating pins 120 and the series of connectors 124 during operation. Additionally, a pair of end openings 128 are configured to align with the locating pins 122. When the movable jaw 112 is in the closed position, the series of heating pins 120 pass through the corresponding openings 126 in the receiving sleeve 116 and make electrical contact with the corresponding connectors 124 in the fixed jaw 120. The locating pins 122 in the illustrated embodiment also pass through a corresponding pair of openings 128 in the receiving sleeve but do not make electrical contact with the fixed jaw 114. However, in some embodiments, the locating pins 122 can also make electrical contact. In the illustrated embodiment, there are seven heating pins 120, and therefore seven corresponding connectors 124 and seven corresponding openings 126. However, in other embodiments, any number of heating pins 120, connectors 124, and openings 126 may be used. In the illustrated embodiment, the heating pins have a generally cylindrical shape with rounded ends. However, in other embodiments, the heating pins 120 may have other shapes, and in still other embodiments, the heating pins 120 need not have the same shape.

[0062] The heating pin 120 in the illustrated embodiment comprises a resistive heating element when an electrical connection is made with a corresponding connector 124. The resistive heating element may be configured to generate heat when an electrical current is directed therethrough. Such heating elements often comprise a metallic material or an electrically conductive ceramic and are configured to generate heat as a result of the electrical resistance associated with passing an electrical current through them. In some embodiments, the material of the heating pin can be the same throughout, but the heating pin 120 in the illustrated embodiment includes an electrically conductive material on each end (e.g., the end of the heating pin 120 that contacts the connector 124 and the end of the heating pin 120 that is connected to the control component 108 and / or the electrical energy source 106) and an electrically resistive material therebetween (e.g., the portion of the heating pin 120 that is configured to contact the aerosol-forming component). Examples of electrically resistive materials include, but are not limited to, titanium, silver, nickel, nichrome, stainless steel, various metal alloys, ceramics such as silicon carbide and silicon nitride, composite materials, and / or any combination thereof. Examples of conductive materials include, but are not limited to, copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite, and / or any combination thereof. Various conductive substrates that may be used with the present disclosure are described in U.S. Patent Application Publication No. 2013 / 0255702 to Griffith et al., the entire disclosure of which is incorporated herein by reference. In some embodiments, the heating pin may include a resistive trace on its surface. In such embodiments, for example, the resistive trace can be added to the pin via various techniques, including, for example, molding, printing, embedding, machining, melt casting, vapor deposition, etc.

[0063] As mentioned above, the receiving sleeve 116 in the illustrated embodiment is configured to receive the heated end of the aerosol source member 104, which can include the aerosol generating component 130. In the open position (e.g., shown in FIG. 2 ), the movable jaw 112 is spaced apart from the fixed jaw 114 and the receiving sleeve 116 and aerosol source member 104; in the closed position (e.g., shown in FIG. 4 ), the movable jaw 112 is adjacent to the fixed jaw 114, with the receiving sleeve 116 and aerosol source member 104 disposed therebetween. In various embodiments, actuation between the open and closed positions (and vice versa) can be achieved in a variety of ways, including manually, such as by a consumer squeezing the jaws together, or automatically or semi-automatically, such as by using a hydrostatic gas spring or other force-displacement mechanism that transmits a directional force to the movable jaw 112. Another example can include a linear displacement motor or other actuator configured to displace the movable jaw 112 between the open and closed positions. Other examples include piezoelectric actuators, ultrasonic ceramic actuators, rotary coil systems, lead screw systems, cam follower mechanisms, gear mechanisms, linkages, and / or any other system configured to generate and transmit directional motion to the movable jaw 112. This motion can be actuated, regardless of mechanism, via a push button and / or through use of the device (e.g., by powering the device, by drawing on the aerosol source member, or by inserting the aerosol source member into the device, etc.), similar to the above. In addition to the methods described above, another method for actuating the movable jaw 112 operates via a small, thin metal probe, such as in the form of a strip or wire, attached perpendicular to the airflow within the device 100. The airflow generated by the user applies a mechanical force to the probe, bending or bending it to some extent. The change in shape, resulting in bending / tension of the probe, causes a change in the electrical resistance of the probe. This change in resistance is transmitted as a pulse and / or signal to the control component 108, which acts as a trigger to actuate the movable jaw 112.

[0064] In the closed position, each heating pin 120 completes an electrical circuit to create an independent, separate heating circuit capable of heating a segment of the aerosol source member via the heating pin 120. However, in the open position, each circuit is incomplete, and the heating pin cannot heat. In various embodiments, the control component 108 may independently control each of the heating circuits. Thus, in the closed position, each heating pin 120 can independently heat a segment of the aerosol source member as controlled by the control component 108. Thus, in some applications, the heating pins 120 may sequentially heat segments of the aerosol source member, while in other applications, the heating pins 120 may heat specific groups of segments of the aerosol source member. As will be appreciated, the present disclosure contemplates any of a variety of heating conditions provided by using independently controlled heating pins 120. As described in more detail below, in some embodiments, control of the heating pins can occur via a user using the device (e.g., via a push button or control panel). Additionally, various indicators may indicate which heaters were used and which were not used for the consumables used in the device.

[0065] It should be noted that while in the illustrated embodiment there are a total of seven separate heating pins 120 corresponding to seven separate heating segments of the aerosol source member 104, in various other embodiments the heating assembly 110 may have any number of separate heating elements corresponding to any number of separate heating segments of the aerosol source member. Furthermore, while in the illustrated embodiment there are multiple separate heating element locations and corresponding separate heating segments that are spaced apart from one another, in other embodiments the separate locations and corresponding separate segments may have different spacings, including, but not limited to, spacings that result in the separate locations and corresponding separate segments being adjacent to one another and / or overlapping one another, as well as inconsistent spacings.

[0066] In the illustrated embodiment, the heating pin 120 is configured to penetrate an aerosol-generating component 130 of the aerosol source member 104 received in the receiving sleeve 116 and make electrical contact with the connector 124 of the fixed jaw 114. Thus, the aerosol-generating component 130 of the illustrated embodiment comprises a solid or semi-solid material (e.g., tobacco or tobacco-derived material, medicinal material, herbal material, etc.). However, in other embodiments, the aerosol-generating component may comprise a gel, liquid, or semi-liquid material.

[0067] As previously mentioned, in various embodiments, the aerosol-generating component may comprise a solid or semi-solid material, which may be tobacco or a tobacco-derived material. In some embodiments, such material may comprise tobacco-containing beads, shredded tobacco, shredded tobacco, reconstituted tobacco material (e.g., extruded or cast sheet substrates), or combinations thereof, and / or a mixture of finely ground tobacco, tobacco extract, spray-dried tobacco extract, or other tobacco forms mixed with optional inorganic materials (such as calcium carbonate), optional flavorings, and aerosol-forming materials to form a substantially solid or moldable (e.g., extrudable) substrate. Gels and suspensions are also available. The construction and formulation of some representative types of solid and semi-solid aerosol-generating components are disclosed in U.S. Pat. No. 8,424,538 to Thomas et al., U.S. Pat. No. 8,464,726 to Sebastian et al., U.S. Patent Application Publication No. 2015 / 0083150 to Conner et al., U.S. Patent Application Publication No. 2015 / 0157052 to Ademe et al., and U.S. Patent Application Publication No. 2017-0000188 to Nordskog et al., filed June 30, 2015, all of which are incorporated herein by reference.

[0068] In various embodiments, the aerosol source member, or a portion thereof, may be wrapped in an overwrap material, which may be formed from any material useful for providing additional structure and / or support to the aerosol source member. In various embodiments, the overwrap material may comprise a material that resists (or promotes) the transfer of heat, which may include paper or other fibrous materials, such as cellulosic materials. The overwrap material may also include at least one filler material embedded or dispersed within the fibrous material. In various embodiments, the filler material may have the form of water-insoluble particles. Additionally, the filler material may incorporate inorganic components. In various embodiments, the overwrap may be formed from multiple layers, such as an underlying bulk layer, and an overlying layer, such as a paper wrapper typical of cigarettes. Such materials may include, for example, lightweight "rag fibers" such as flax, hemp, sisal, rice straw, and / or esparto. Additional description regarding the configuration of overwrap materials that may be used with the present disclosure can be found in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety. In additional embodiments, the overwrap material may have one or more of the following properties: it may be impermeable to aerosol migration, it may have the ability to withstand elevated temperatures of interest, it may promote radial heat transfer from the heater to the tobacco stick material, it may resist axial heat transfer along the tobacco stick, away from the heated segment, and / or it may have a relatively low thermal mass so as not to inhibit the rapid temperature rise of the heated segment. In one embodiment, the overwrap material may be stainless steel foil, which in some embodiments may be about 0.001 inches thick. In another embodiment, the overwrap material may be aluminum foil.

[0069] In various embodiments, the mouth end of the aerosol source member may include a filter, which may be made, for example, from a cellulose acetate material, a polypropylene material, or a polylactic acid material. In various embodiments, the filter may enhance the structural integrity of the mouth end of the aerosol source member and / or provide optional filtration and / or resistance to suction. For example, articles according to the present disclosure may exhibit a pressure drop of about 50 to about 250 millimeters of water column at an airflow of 17.5 cc / sec. In further embodiments, the pressure drop may be about 60 millimeters of water column to about 180 millimeters of water column, or about 70 millimeters of water column to about 150 millimeters of water column. Pressure drop values ​​may be measured using a Filtrona Filter Test Station (CTS series) available from Filtrona Instruments and Automation Ltd. or a Quality Test Module (QTM) available from Cerulean Division of Molins, PLC. The length of the filter at the mouth end of the aerosol source member can vary, such as from about 2 mm to about 20 mm, from about 5 mm to about 20 mm, or from about 10 mm to about 15 mm. In some embodiments, the filter may include individual segments. For example, some embodiments may include a segment that provides filtration, a segment that provides resistance to draw, a hollow segment that provides space for the aerosol to cool, a segment that provides structural integrity, other filter segments, and any one or any combination of the above. In some embodiments, the filter may be separate from the overwrap, or the filter may be held in place by the overwrap.

[0070] Additional exemplary types of packaging materials, packaging components, and treated packaging materials that can be used for overwraps in the present disclosure are described in U.S. Pat. No. 5,105,838 to White et al., U.S. Pat. No. 5,271,419 to Arzonico et al., U.S. Pat. No. 5,220,930 to Gentry, U.S. Pat. No. 6,908,874 to Woodhead et al., U.S. Pat. No. 6,929,013 to Ashcraft et al., U.S. Pat. No. 7,195,019 to Hancock et al., U.S. Pat. No. 7,276,120 to Holmes, U.S. Pat. No. 7,275,548 to Hancock et al., WO 01 / 08514 to Fournier et al., and PCT Publication No. WO 03 / 043450 to Hajaligol et al., which are incorporated by reference herein in their entireties. Representative packaging materials are commercially available from Schweitzer-Maudit International as RJ Reynolds Tobacco Company grades 119, 170, 419, 453, 454, 456, 465, 466, 490, 525, 535, 557, 652, 664, 672, 676, and 680. The porosity of the packaging material can vary, frequently from about 5 CORESTA units to about 30,000 CORESTA units, often from about 10 CORESTA units to about 90 CORESTA units, and frequently from about 8 CORESTA units to about 80 CORESTA units.

[0071] To maximize delivery of aerosol and flavors that might otherwise be diluted by radial (i.e., outward) air penetration through the overwrap, one or more layers of non-porous cigarette paper may be used to encase the aerosol source member (with or without the overwrap present). Examples of suitable non-porous cigarette paper are commercially available from Kimberly-Clark Corp. as KC-63-5, P878-5, P878-16-2, and 780-63-5. Preferably, the overwrap is a material that is substantially impermeable to vapors formed during use of the article of the present invention. Optionally, the overwrap can comprise a resilient paperboard material, foil-backed paperboard, metal, polymeric material, or the like, which can be surrounded by a wrap of cigarette paper. The overwrap can also include tipping paper surrounding the components and, optionally, can be used to attach a filter material to the aerosol source member, as described elsewhere herein. In various embodiments, other components may be present between the aerosol-generating component and the mouth end of the aerosol source member, and the mouth end may include a filter. For example, in some embodiments, one or any combination of the following may be disposed between the aerosol-generating component and the mouth end: an air gap; a phase-change material for cooling the air; a flavor-releasing medium; ion-exchange fibers capable of selective chemical adsorption; aerogel particles as a filter medium; and other suitable materials.

[0072] Tobacco materials useful in the present disclosure may vary and may include, for example, flue-cured, burley, Oriental or Maryland, dark, dark-flavored, and rustica tobaccos, as well as other rare or specialty tobaccos, or blends thereof. Tobacco materials may also include so-called "blend" forms and processed forms, such as processed tobacco stems (e.g., cut roll stems or cut puff stems), volume-expanded tobacco (e.g., puffed tobacco, advantageously in cut filler form, e.g., dry ice expanded tobacco (DIET)), and reconstituted tobacco (e.g., reconstituted tobacco produced using a paper-forming type process or a cast sheet type process). Various representative tobacco types, processed tobacco types, and tobacco blend types are described in U.S. Patent Nos. 4,836,224 to Lawson et al., 4,924,888 to Perfetti et al., 5,056,537 to Brown et al., 5,159,942 to Brinkley et al., 5,220,930 to Gentry, and 5,360,023 to Blakley et al., all of which are incorporated by reference in their entireties. No. 6,701,936 to Shafer et al., U.S. Pat. No. 7,011,096 to Li et al., U.S. Pat. No. 7,017,585 to Li et al., U.S. Pat. No. 7,025,066 to Lawson et al., U.S. Patent Application Publication No. 2004-0255965 to Perfetti et al., PCT Publication No. WO 02 / 37990 to Bereman, and Fund. Appl. Toxicol., 39, pp. 11-17 (1997). Additional exemplary tobacco compositions that may be useful in smoking devices, including those according to the present disclosure, are disclosed in U.S. Pat. No. 7,726,320 to Robinson et al., which is incorporated herein by reference in its entirety.

[0073] Additionally, the aerosol-generating component may include an inert substrate into which an inhalable substance or its precursor is incorporated or otherwise deposited. For example, a liquid containing the inhalable substance may be coated onto, absorbed into, or adsorbed onto the inert substrate, such that upon application of heat, the inhalable substance is released in a form that can be drawn from the article of the present invention by application of positive or negative pressure. In some embodiments, the aerosol-generating component may comprise a flavorful, aromatic tobacco blend in cut filler form. In another embodiment, the aerosol-generating component may include reconstituted tobacco material, such as those described in U.S. Pat. Nos. 4,807,809 to Pryor et al., 4,889,143 to Pryor et al., and 5,025,814 to Raker, the entire disclosures of which are incorporated herein by reference.

[0074] In some embodiments, the aerosol-generating component may include tobacco, tobacco components and / or tobacco-derived materials that have been processed, manufactured, produced and / or processed to incorporate an aerosol precursor composition (e.g., a humectant, e.g., propylene glycol, glycerin, etc.) and / or at least one flavoring agent, as well as a flame retardant (e.g., diammonium phosphate and / or another salt) configured to help prevent ignition, thermal decomposition, combustion and / or charring of the aerosol delivery component by a heat source. Various modes and methods for incorporating tobacco into smoking articles, particularly smoking articles designed to intentionally prevent the combustion of substantially any tobacco within the smoking article, are described in U.S. Pat. No. 4,947,874 to Brooks et al., U.S. Pat. No. 7,647,932 to Cantrell et al., U.S. Pat. No. 8,079,371 to Robinson et al., U.S. Pat. No. 7,290,549 to Banerjee et al., and U.S. Patent Application Publication No. 2007 / 0215167 to Crooks et al., the entire disclosures of which are incorporated herein by reference.

[0075] In some embodiments, other flame-retardant / flame-retardant materials and additives may be included in the aerosol-generating component, including organophosphorus compounds, borax, hydrated alumina, graphite, potassium tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Others, such as nitrogen phosphonates, monoammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ethanolammonium borate, ammonium sulfamate, halogenated organic compounds, thiourea, and antimony oxide, may also be used. In each aspect of the flame-retardant, flame-retardant, and / or char-retardant materials used in the aerosol-generating component and / or other components (whether alone or in combination with each other and / or other materials), the desired properties are preferably provided without undesirable outgassing, chemical reactivity, or melt-type behavior. Additional flavors, flavorings, additives, and other possible enhancing ingredients are described in U.S. Patent Application Serial No. 15 / 707,461 to Phillips et al., incorporated herein by reference in its entirety.

[0076] In addition to the inhalable substance (e.g., typically a flavor, nicotine, or pharmaceutical agent), the aerosol-generating component may comprise one or more aerosol- or vapor-forming materials, such as a polyhydric alcohol (e.g., glycerin, propylene glycol, or mixtures thereof) and / or water. Representative types of aerosol-forming materials are described in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al. and U.S. Pat. No. 5,101,839 to Jakob et al., 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), all of which are incorporated herein by reference. Preferred aerosol-forming materials produce a visible aerosol when sufficient heat is applied to them, and highly preferred aerosol-forming materials produce an aerosol that can be considered "smoke-like." Additional tobacco materials, such as tobacco aroma oil, tobacco essence, spray-dried tobacco extract, freeze-dried tobacco extract, or tobacco dust, may be combined with the vapor-forming or aerosol-forming material. It should also be understood that the inhalable substance itself may be in a form that, upon heating, releases the inhalable substance as a vapor, an aerosol, or a combination thereof. In other embodiments, the inhalable substance may not necessarily be released in the form of a vapor or aerosol, but the vapor-forming or aerosol-forming material with which it may be combined may form a vapor or aerosol upon heating and essentially function as a carrier for the inhalable substance itself. Thus, the inhalable substance may be characterized as being coated on a substrate, absorbed into a substrate, adsorbed onto the surface of a substrate, or a natural component of the substrate (i.e., the material forming the substrate, e.g., tobacco or tobacco-derived material). Similarly, aerosol-forming or vapor-forming materials may be similarly characterized.In certain embodiments, the aerosol-generating component may specifically comprise a substrate containing an inhalable substance and a separate aerosol-forming material contained therein. Thus, during use, the substrate may be heated, and the aerosol-forming material may be volatilized into vapor form, entraining the inhalable substance therewith. In certain examples, the aerosol-generating component may comprise a solid substrate onto which a tobacco slurry and an aerosol-forming material and / or vapor-forming material are coated or absorbed or adsorbed. The substrate component may be any material that does not burn or otherwise degrade at the temperatures described herein, achieved by the heating element to facilitate release of the inhalable substance. For example, paper materials, including tobacco paper (e.g., paper-like materials containing tobacco fiber and / or reconstituted tobacco), may be used. Thus, in various embodiments, the aerosol-generating component may be characterized as comprising an inhalable substance; alternatively, comprising an inhalable substance and a separate aerosol- or vapor-forming agent; alternatively, comprising an inhalable substance and a substrate; or alternatively, comprising an aerosol-generating component, a separate aerosol- or vapor-forming agent, and a substrate. Thus, the substrate may contain an inhalable substance and one or both of an aerosol or vapor forming agent.

[0077] Optionally, the tobacco material or aerosol-generating component may further contain other ingredients, such as sugar, glycerin, vanilla, cocoa, licorice, and other flavoring materials, such as menthol. Exemplary plant-derived compositions that can be used are disclosed in U.S. Patent Application Publication No. 2012 / 0152265 to Dube et al. and U.S. Patent No. 9,107,453 to Dube et al. The selection of such additional ingredients can vary based on factors such as the sensory characteristics desired in the article, and the present disclosure is intended to encompass any such additional ingredients that would be readily apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See, for example, Gutcho's *Tobacco Flavoring Substances and Methods*, Noyes Data Corp. (1972) and Leffingwell et al.'s *Tobacco Flavoring for Smoking Products* (1972).

[0078] The inhalable substance and / or the separate vapor-forming material can be provided on the aerosol-generating component in various configurations. For example, both materials can be associated with the substrate such that the concentration of each material along the length of the substrate is substantially constant (e.g., if the substrate is divided into multiple longitudinal segments, the total concentration of the material in each individual segment can be substantially similar, e.g., varying by less than 10%, less than 5%, or less than 2% by weight). In other embodiments, one or both of the materials can be present in a defined pattern. For example, the pattern can be a gradient in which the concentration continuously increases or decreases along the length of the substrate. In this way, the first puff with the article may provide a significantly greater or lesser amount of inhalable substance than the amount of inhalable substance in the last puff. The gradient can also be designed to provide a uniform production of inhalable substance throughout the entire puff. Furthermore, the pattern can be such that a large amount of inhalable substance is provided at a certain point along the length of the substrate (e.g., corresponding to the first puff with the article, the last puff, or some intermediate puff). In light of the present disclosure, any variety of such patterns can be envisioned, and such variations are also encompassed by the present disclosure. Such patterning can also be applied to additional ingredients (e.g., flavorings) described herein. For example, a large amount of flavoring can be provided on the substrate at a position substantially corresponding to the last puff or the last two or three puffs using the article. The release of such flavoring can notify the consumer that the last puff using the device is approaching or has been achieved. Various other configurations and components that can be included in the aerosol-generating components of the present disclosure are described in U.S. Patent No. 9,078,473 to Worm et al., the entire contents of which are incorporated herein by reference.

[0079] In some aspects of the present disclosure, the aerosol-generating component can be configured as an extruded material, as described in U.S. Patent Application Publication No. 2012 / 0042885 to Stone et al., which is incorporated herein by reference in its entirety. In still other aspects, the aerosol-generating component can be configured as an extruded structure and / or substrate that includes or consists essentially of tobacco, tobacco-related materials, glycerin, water, and / or binder materials, although certain formulations do not include binder materials. In various embodiments, the binder material can be any binder material commonly used in tobacco formulations, including, for example, carboxymethylcellulose (CMC), gums (e.g., guar gum), xanthan, pullulan, and / or alginate. According to some aspects, the binder material included in the aerosol delivery component can be configured to substantially maintain the structural shape and / or integrity of the aerosol delivery component. Various exemplary binders, binder properties, binder uses, and binder amounts are described in U.S. Patent No. 4,924,887 to Raker et al., which is incorporated herein by reference in its entirety.

[0080] In some embodiments, the aerosol-generating component can be further configured to substantially maintain its structure throughout the aerosol-generation process. That is, the aerosol-generating component is configured to substantially maintain its shape throughout the aerosol-generation process (i.e., the aerosol delivery component does not continuously deform under applied shear stress). In some embodiments, the aerosol-generating component may contain liquid and / or some moisture content, but in some embodiments, the aerosol-generating component is configured to remain substantially solid throughout the aerosol-generation process and substantially maintain its structural integrity throughout the aerosol-generation process. Exemplary tobacco and / or tobacco-related materials suitable for substantially solid aerosol delivery components are described in U.S. Patent Application Publication No. 2015 / 0157052 to Ademe et al., U.S. Patent Application Publication No. 2015 / 0335070 to Sears et al., U.S. Patent No. 6,204,287 to White, and U.S. Patent No. 5,060,676 to Hearn et al., each of which is incorporated herein by reference in its entirety.

[0081] In yet another embodiment, the aerosol-generating component may include an extruded structure and / or substrate formed from marumerized and / or non-marumerized tobacco. Marumerized tobacco is known, for example, from U.S. Patent No. 5,105,831 to Banerjee et al., which is incorporated herein by reference in its entirety. Marumerized tobacco comprises about 20 to about 50 percent (by weight) of a tobacco blend in powder form, along with glycerol (about 20 to about 30 percent by weight), calcium carbonate (typically about 10 to about 60 percent by weight, often about 40 to about 60 percent by weight), and a binder and / or flavoring agent as described herein.

[0082] In various embodiments, the aerosol-generating component wall can be formed substantially from a material that can naturally contain an inhalable substance therein (e.g., cigarette paper), or can be formed from any additional material (e.g., paper) that can have an inhalable substance and / or vapor-forming or aerosol-forming agent incorporated therein. In addition to the inhalable substance and / or vapor-forming or aerosol-forming substance, the substrate wall may contain additional components. For example, a vapor barrier may be included on the outer surface of the aerosol-generating component wall. Preferably, the vapor barrier is disposed on the wall surface adjacent to (or in contact with) the heating element when the aerosol-generating component is heated. In certain embodiments, the vapor barrier may be formed from an electrically insulating material or may include a layer of electrically insulating material that can contact the heating element. For example, a metal foil may be used as the vapor barrier, and the foil may have an insulating layer (e.g., a metal oxide layer) in contact with the heating element to prevent vapor or aerosol release into the outer volume of the aerosol-generating component and facilitate vapor or aerosol release into the annular space defined by the inner surface of the aerosol-generating component wall. Any vapor barrier material may be used, such as metal foil.

[0083] In further embodiments, the aerosol-generating component can be formed from a material that softens or changes phase (particularly from solid to molten) at about the operating temperature of the article. For example, the aerosol-generating component can be a wax or gel, and the inhalable substance can be incorporated therein. In such embodiments, it can be particularly useful to include a vapor barrier (or similar material) that provides support to the aerosol-generating component and substantially prevents the aerosol-generating component from contacting the heating element. Similarly, the aerosol-generating component can include a vapor barrier layer coated with the inhalable substance and / or aerosol-forming material. For example, one or more of such coating materials can be in a microencapsulated form that preferably releases its components at temperatures within one or more of the operating ranges described elsewhere herein. Microencapsulation techniques useful in such embodiments are disclosed, for example, in U.S. Patent No. 4,464,434 to Davis.

[0084] In some embodiments, the aerosol-generating component may include tobacco components (e.g., reconstituted cast tobacco sheets or tobacco beads) or non-tobacco components (e.g., herbs, paper, cellulose, etc.) including one or more of a binder component, a humectant component, a flavor component, a humectant component, and a casing material. In some embodiments, the binder component may include, for example, cellulose and / or guar gum. In some embodiments, the humectant component may contain, for example, about 15-25% glycerol, about 14.5% sorbitol, and / or about 3-10% propylene glycol. In some embodiments, the flavor component may include, for example, acetic acid, citric acid, acetoin, lactic acid, menthol, peppermint oil, carob extract, cocoa products, licorice extract, invert sugar, and / or sucrose. In some embodiments, the humectant component may include, for example, about 15-25% water.

[0085] As noted above, the end of the aerosol source member 104 opposite the mouth end is sized and shaped for insertion into the receiving sleeve 116. In various embodiments, the outer diameter (or other dimension, depending on the particular cross-sectional shape of the embodiment) of the aerosol source member 104 is preferably slightly smaller than the inner diameter (or other dimension) of the receiving sleeve 116. Ideally, the difference in their respective diameters is small enough so that the aerosol source member 104 fits snugly within the receiving sleeve 116 and frictional forces prevent the aerosol source member from moving without the application of force.

[0086] As mentioned above, in some embodiments, the aerosol source member may include an overwrap. If present, the overall length of the overwrap can vary from approximately the same as the length of the aerosol-generating component to approximately twice the length of the aerosol-generating component. Thus, the aerosol-generating component may have a length that is up to about 50%, up to about 30%, or up to about 10% shorter than the length of the overwrap. Preferably, the aerosol-generating component may have a length that is at least 10%, at least 15%, or at least 20% shorter than the length of the overwrap. More specifically, the distance that the overwrap extends beyond the aerosol-generating component may be about 5%, 10%, 15%, 20%, 25%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 100% of the length of the aerosol-generating component.

[0087] The overwrap can also function to provide particular properties to the mouth end of the aerosol source member. For example, the structure and / or shape and / or dimensions of the overwrap can function to provide the feel of a traditional cigarette in the user's mouth. Additionally, as mentioned above, the overwrap may include a filter (e.g., cellulose acetate or polypropylene) positioned proximate the mouth end of the cartridge to enhance its structural integrity and / or provide optional filtration capabilities and / or resistance to draw.

[0088] The embodiments shown in Figures 1-4 describe a heating assembly in which, in the closed position, a series of heating elements (in these embodiments, a series of heating pins 120) penetrate the aerosol source member 104. In other embodiments, the series of heating elements need not penetrate the aerosol source member, but rather may extend to some depth within the aerosol source member. For example, Figure 5 shows a perspective view of components of a heating assembly of an aerosol delivery device according to another exemplary embodiment of the present disclosure. In particular, Figure 5 shows a movable jaw 212 that can be used in combination with a housing, electrical energy source, control components, and aerosol delivery device similar to those described above. In various embodiments, one or more of these components can be different (or omitted), but please refer to the above description related to these components.

[0089] Although other materials are possible, in the illustrated embodiment, the movable jaw 212 can be made from a metallic material (e.g., aluminum, stainless steel, metal alloy, etc.), a ceramic material (e.g., alumina, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, boron nitride, etc.), a polymeric material (e.g., polyimide, thermoplastic polyimide, polybenzimidazole, polyetheretherketone, polypropylene, high-density polyethylene, etc.), a composite material, and / or any combination thereof. As described in more detail below, the movable jaw 212 of the illustrated embodiment is configured to move between an open position in which the movable jaw is spaced apart from the fixed jaw and a closed position in which the movable jaw 212 is adjacent to the fixed jaw. In many aspects, the movable jaw 212 can be configured for use with a fixed jaw similar to the fixed jaw described with respect to FIGS. 1-4 , see the discussion above. However, as described in more detail below, the movable jaw 212 of the illustrated embodiment is configured for use with a fixed jaw that need not include an electrical connector.

[0090] The movable jaw 212 can be configured for use with a receiving sleeve similar to the receiving sleeve described with respect to Figures 1-4, and therefore, reference is made to the above description. As noted above, the receiving sleeve in some embodiments may have a substantially cylindrical shape configured to receive at least the heated end of the aerosol source member. In such embodiments, the movable jaw 212 and the fixed jaw may each have an interior shape configured to substantially surround the receiving sleeve, and thus at least the heated end of the aerosol source member. In particular, the inner surface 218 of the movable jaw 212 and the inner surface of the fixed jaw together form a shape complementary to the shape of the receiving sleeve. In this manner, when the movable jaw 212 is in the closed position, the interior surfaces together surround the receiving sleeve.

[0091] The movable jaw 212 in the illustrated embodiment includes a series of individual heating elements 220 extending outward from its inner surface 218. The movable jaw 212 in the illustrated embodiment also includes a pair of locating pins 222 extending outward from the inner surface 218 of the movable jaw 212; however, it should be noted that in some embodiments, the locating pins 222 need not be present. In the embodiments described above with reference to FIGS. 1-4 , the series of heating pins are configured to electrically connect (in the closed position) with a series of corresponding connectors located on the fixed jaw to create a closed heating circuit. However, in the illustrated embodiment, the series of heating elements 220 comprise individual closed resistive heating circuits, each configured to heat a segment of the aerosol source member. Thus, when the movable jaw 212 is in the closed position, the heating elements 220 extend to a certain depth within the aerosol source member. For example, in some embodiments, the heating elements 220 penetrate less than halfway through the aerosol source member. In other embodiments, the heating elements 220 penetrate approximately halfway through the aerosol source member. In still other embodiments, the heating element 220 penetrates more than halfway through the aerosol source member. Note that in some embodiments, individual heating elements 220 within a series of heating elements 220 may extend to different depths within the aerosol source member.

[0092] While the heating element 220 in the illustrated embodiment comprises a resistive heating element and has a blade-like shape (e.g., a relatively thin, flat configuration with an angled top), in other embodiments, the heating element 220 may have other shapes, such as, for example, a generally cylindrical shape with the heating element disposed around its outer surface. The resistive heating element can be configured to generate heat when an electric current is conducted therethrough. Such heating elements often comprise a metallic material and are configured to generate heat as a result of the electrical resistance associated with passing an electric current through them. In the illustrated embodiment, the heating element includes a heating element wire and / or trace 220a (hereinafter referred to as "heating trace") constructed from an electrically resistive material. Examples of electrically resistive materials include, but are not limited to, titanium, silver, nickel, nichrome, stainless steel, tungsten, indium tin oxide, various metal alloys, ceramics such as silicon carbide and silicon nitride, composite materials, and / or any combination thereof. In various embodiments, each heating trace 220a can be secured onto body portion 220b via various techniques including, for example, molding, printing, embedding, machining, melt casting, vapor deposition, etc. In various embodiments, body portion 220b can be constructed from a metallic material (e.g., aluminum, stainless steel, metal alloy, etc.). Note that in other embodiments, body 220b can be constructed from another material including, for example, a ceramic material (e.g., alumina, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, oxides of metals such as zinc oxide, zirconium oxide, copper oxide, etc.), a polymeric material (e.g., polyimide, thermoplastic polyimide, polybenzimidazole, polyetheretherketone, polypropylene, high density polyethylene, etc.), a composite material, and / or any combination thereof.

[0093] Similar to the embodiment described above with respect to FIGS. 1-4 , the receiving sleeve in the illustrated embodiment is configured to receive the heated end of an aerosol source member, which may include an aerosol generating component. In the open position, the movable jaw 212 is spaced apart from the fixed jaw and the receiving sleeve and aerosol source member; in the closed position, the movable jaw 212 is adjacent to the fixed jaw, with the receiving sleeve and aerosol source member disposed therebetween. In various embodiments, actuation between the open and closed positions (and vice versa) can be achieved in a variety of ways, including manually (e.g., a consumer may push the jaws together) or automatically or semi-automatically, such as by using a hydrostatic gas spring or other force-displacement mechanism that transmits a directional force to the movable jaw 212. Another example can include a linear displacement motor or other actuator configured to linearly displace the movable jaw 212 between the open and closed positions. Other examples include a piezoelectric actuator, an ultrasonic ceramic actuator, a rotating coil system, a lead screw system, and / or any other system configured to generate and transmit directional and / or rotational motion to the movable jaw 212. This movement can be actuated, regardless of mechanism, via a push button, and / or through use of the device (e.g., by supplying power to the device, by aspirating the aerosol source member, or by inserting the aerosol source member into the device, etc.), and / or via electrical resistance probe methods, as described above.

[0094] Figure 6 shows a top view and a perspective view of certain components of a heating assembly of an aerosol delivery device in an open position, and Figure 7 shows a bottom view of the components shown in the open and closed positions, according to another exemplary embodiment of the present disclosure. In particular, Figures 6 and 7 show a multi-piece movable jaw 312 that can be used in combination with a housing, electrical energy source, control components, and aerosol delivery device similar to those described above. In various embodiments, one or more of these components may be different (or omitted), but please refer to the above description related to these components.

[0095] In various embodiments, the multi-piece movable jaw may include any number of sections, including, for example, as few as two sections or as many as four or more sections. In the illustrated embodiment, the multi-piece movable jaw 312 comprises three separate sections: first movable jaw section 312-1, second movable jaw section 312-2, and third movable jaw section 312-3. Although other materials are possible, in the illustrated embodiment, the movable jaw sections 312-1, 312-2, 312-3 can be made from any of the following materials: metallic materials (e.g., aluminum, stainless steel, metal alloys, etc.), ceramic materials (e.g., alumina, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, etc.), polymeric (e.g., polyimide, thermoplastic polyimide, polybenzimidazole, polyetheretherketone, polypropylene, high-density polyethylene, etc.), composite materials, and / or any combination thereof. As described in more detail below, the movable jaw sections 312-1, 312-2, 312-3 are configured to move together between an open position in which the movable jaw sections 312-1, 312-2, 312-3 are spaced apart from one another and a closed position in which the movable jaw sections 312-1, 312-2, 312-3 are adjacent to one another. In the illustrated embodiment, no fixed jaws need be present because the configuration of the movable jaw sections 312-1, 312-2, 312-3 in the closed position creates a substantially closed configuration that surrounds the aerosol source member (and in some embodiments, a receiving sleeve that can be included).

[0096] Similar to the above, the receiving sleeve in some embodiments may have a generally cylindrical shape configured to receive at least the heated end of the aerosol source member. In such embodiments, the movable jaw sections 312-1, 312-2, 312-3 may have an interior shape configured to substantially surround the receiving sleeve, and thus at least the heated end of the aerosol source member. In particular, the inner surfaces 318-1, 318-2, 318-3 of the movable jaw sections 312-1, 312-2, 312-3 together form a shape complementary to the shape of the receiving sleeve. In this manner, when the movable jaw sections 312-1, 312-2, 312-3 are in the closed position, the inner surfaces together surround the receiving sleeve.

[0097] Each movable jaw section 312-1, 312-2, 312-3 in the illustrated embodiment includes a series of heating elements 320-1, 320-2, 312-3 extending outward from their respective inner surfaces 318-1, 318-2, 318-3. It will be understood that in other embodiments, additional or fewer heating elements can be included on each movable jaw section. For example, in one embodiment, a single heating element can be included on each of the movable jaw sections such that there are three heating elements total. While other embodiments may differ (see the top view shown in FIG. 6 ), the series of heating elements 320-1, 320-2, 312-3 in the illustrated embodiment have a staggered configuration such that the individual heating elements of the series of heating elements 320-1, 320-2, 312-3 are not aligned with one another and instead overlap when the movable jaw sections 312-1, 312-2, 312-3 are in the closed position. In the illustrated embodiment, each of the series of heating elements 320-1, 320-2, 312-3 comprises a separate closed resistive heating circuit configured to heat a segment of the aerosol source member. Thus, when the movable jaw sections 312-1, 312-2, 312-3 are in the closed position, the heating elements 320-1, 320-2, 320-3 extend to a certain depth into the aerosol source member. For example, in the illustrated embodiment, the heating elements 320-1, 320-2, 320-3 penetrate more than halfway through the aerosol source member. However, in other embodiments, the heating elements 320-1, 320-2, 320-3 may penetrate approximately halfway through the aerosol source member, and in still other embodiments, the heating elements 320-1, 320-2, 320-3 may penetrate less than halfway through the aerosol source member.

[0098] Although the heating elements 320-1, 320-2, and 320-3 in the illustrated embodiment comprise resistive heating elements and have a blade-like shape, in other embodiments, the heating elements 320-1, 320-2, and 320-3 may have other shapes. Resistive heating elements can be configured to generate heat when an electric current is conducted therethrough. Such heating elements often comprise a metallic material and are configured to generate heat as a result of the electrical resistance associated with passing an electric current through them. Referring to FIG. 7 , each of the heating elements 320-1, 320-2, and 320-3 includes a heating element trace 320a-1, 320a-2, and 320a-3 constructed from an electrically resistive material. Examples of electrically resistive materials include, but are not limited to, titanium, silver, nickel, nichrome, stainless steel, indium tin oxide, various metal alloys, ceramics such as silicon carbide and silicon nitride, composite materials, and / or any combination thereof. In various embodiments, the heat traces 320a-1, 320a-2, and 320a-3 can be fixed onto the bodies 320b-1, 320b-2, 320b-3 via printing, embedding, machining, squeezing, etc. In various embodiments, the heat traces can be fixed onto the bodies 320b-1, 320b-2, 320b-3 constructed from a metallic material (e.g., aluminum, stainless steel, a metal alloy, etc.). It should be noted that in other embodiments, the body 220b can be constructed from another material, including, for example, a ceramic material (e.g., alumina, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, etc.), a polymeric material (e.g., polyimide, thermoplastic polyimide, polybenzimidazole, polyetheretherketone, polypropylene, high-density polyethylene, etc.), a composite material, and / or any combination thereof.

[0099] In the illustrated embodiment, a receiving sleeve (not shown) can be configured to receive the heated end of the aerosol source member, although in other embodiments, the receiving sleeve may not be present. In the open position, the movable jaw sections 312-1, 312-2, and 312-3 are spaced apart from each other and from the receiving sleeve and the aerosol source member. In the closed position, the movable jaw sections 312-1, 312-2, and 312-3 are adjacent to each other, with the receiving sleeve and the aerosol source member disposed therebetween. In various embodiments, actuation between the open and closed positions (and vice versa) can be achieved in a variety of ways, including manually (e.g., a consumer may push the jaws together) or automatically or semi-automatically, such as by using a hydrostatic gas spring or other force-displacement mechanism that transmits a directional force to the movable jaws 312-1, 312-2, and 312-3. Another example can include a linear displacement motor or other actuator configured to displace the movable jaw sections 312-1, 312-2, and 312-3 between the open and closed positions. Other examples include piezoelectric actuators, ultrasonic ceramic actuators, rotary coil systems, lead screw systems, cam follower mechanisms, gear mechanisms, linkages, and / or any other system configured to generate and transmit directional and / or rotational motion to the movable jaw sections 312-1, 312-2, 312-3. Similar to the above, regardless of the mechanism, this motion can be actuated via a push button and / or through use of the device (e.g., by applying power to the device, by drawing aspirate on the aerosol source member, by inserting the aerosol source member into the device, etc.), and / or via electrical resistance probing methods.

[0100] 8 shows a perspective view of an aerosol delivery device 400 according to another exemplary embodiment of the present disclosure, and FIG. 9 shows a perspective exploded view of the aerosol delivery device 400. In particular, the aerosol delivery device 400 of the illustrated embodiment includes a first housing portion 402, a second housing portion 404, a mouthpiece 406, an aerosol source member 408 (including aerosol generating components, an overwrap, and a filter), a heating assembly 410, and an indicator 412. The aerosol delivery device 400 further includes an electrical energy source (not visible, e.g., a battery, which may be rechargeable, and / or a rechargeable supercapacitor) and a control component (not visible, e.g., a microprocessor, either separately or as part of a microcontroller, a printed circuit board (PCB) including the microprocessor and / or microcontroller, etc.). As described in more detail below, the heating assembly 410 of various embodiments comprises a series of independent and separate heating elements, each configured to heat a segment of the aerosol source element 408.

[0101] In various embodiments, one or both of the control component and the electrical energy source can be coupled with first housing portion 402 and / or second housing portion 404. For purposes of this application, the phrase "coupled" when used with respect to one component as compared to another component may encompass embodiments in which one component is disposed within another component and / or embodiments in which one component is separate but otherwise operably connected to another component. For example, in the illustrated embodiment, both the control component and the electrical energy source are disposed within first housing portion 402. However, in other embodiments, one or both of the control component and the electrical energy source can be disposed in different components. Additional information regarding the control component and the electrical energy source is provided below.

[0102] In various embodiments, the first housing portion 402 and the second housing portion 404 can be mechanically engaged together in various ways. For example, in some embodiments, the first housing portion 402 and the second housing portion 404 may engage via a threaded connection. In other embodiments, the first housing portion 402 and the second housing portion 404 may engage via an interference fit or a friction fit. In other embodiments, the first housing portion 402 and the second housing portion 404 may engage via a magnetic connection. In other embodiments, the first housing portion 402 and the second housing portion 404 may engage via a snap-fit ​​connection. In still other embodiments, the first housing portion 402 and the second housing portion 404 engage via a bayonet-style connection including a male component (e.g., a pin) and a female component (e.g., an L-shaped slot). It should be noted that in some embodiments, the first housing portion 402 and the second housing portion 404 may comprise a single, integral housing portion.

[0103] In the illustrated embodiment, although other embodiments may differ, the aerosol source member 408 is inserted into the second housing portion 404 by removing the mouthpiece 406 and inserting the aerosol source member 408 so that it is positioned near (e.g., above) the heating assembly 410. In the illustrated embodiment, there is a single series of heating elements 420 extending from the heating assembly frame 422 such that the single series of heating elements 420 is configured to be positioned on one side of the aerosol source member 408. However, in other embodiments, there may be two or more series of heating elements 420 configured to be positioned on both sides of the aerosol source member 408. After insertion of the aerosol source member 408, the mouthpiece 406 can then be reinserted into the second housing portion 404 so that the filter end of the aerosol source member 404 is closest to the mouthpiece 406. As such, one or both of the second housing portion 404 or the aerosol source member 408 may be keyed or otherwise include a stop or positioning feature to facilitate proper positioning thereof. In various embodiments, the first housing portion 402, the second housing 404 and / or the mouthpiece 406 may be detachable from one another, and thus any one or all may be interchangeable.

[0104] In some embodiments, first housing portion 402 and / or second housing portion 404 may also include one or more push buttons configured to activate certain operations of device 400, such as, for example, turning on the device and initiating heating of heating assembly 410 (e.g., one or more heating elements of the heating assembly). As described in further detail below, in various embodiments, aerosol source member 408 may comprise an aerosol generating component configured to be disposed near heating assembly 410 and a filter configured to be disposed near mouthpiece 406. It should be noted that, although first housing portion 402, second housing portion 404, and aerosol source member 408 in the illustrated embodiment have a substantially elongated rectangular cuboid shape, in other embodiments, first housing portion 402, second housing portion 404, and / or aerosol source member 408 may have any other shape, including, for example, the shape of a traditional cigarette or cigar.

[0105] In certain embodiments, the first housing portion 402, the second housing portion 404, and / or the aerosol source member 408 can be referred to as disposable or reusable. For example, the electrical energy source and / or the housing portion 402 containing the electrical energy source may comprise a replaceable or rechargeable battery, a solid-state battery, a thin-film solid-state battery, a rechargeable supercapacitor, etc., and thus may be combined with any type of charging technology, including connection to a wall charger, a connection to an automobile charger (i.e., cigarette lighter socket), a connection to a computer via a Universal Serial Bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), etc., a connection to a photovoltaic cell (sometimes called a solar cell) or solar panel, a wireless charger, such as a charger using inductive wireless charging (e.g., including wireless charging compliant with the Qi wireless charging standard by the Wireless Power Consortium (WPC)), or a radio frequency (RF)-based charger. An example of an inductive wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is incorporated herein by reference in its entirety. Additionally, in some embodiments, the aerosol source member 408 and / or the second housing portion 404 containing the aerosol source member, and / or the mouthpiece 406 may comprise a disposable device. Disposable components for use with the control body are disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0106] In various embodiments, the control component may include control circuitry (which may be connected to additional components, as further described herein) that may be connected to a source of electrical energy by conductive wires. In various embodiments, the control component may control when and how the heating assembly 410 (e.g., one or more heating elements of the heating assembly) receives electrical energy to heat the aerosol-generating component to release an inhalable substance for inhalation by the consumer. Such control (e.g., control of heating stages, including pre-heating and final heating) may be associated with the actuation of a pressure-sensitive switch, or the like, described in further detail below. Note that the terms “connected” or “coupled” should not be interpreted as requiring a direct connection without intervening components. Rather, these terms can encompass a direct connection and / or a connection via one or more intervening components. Thus, in various embodiments, these terms will be understood to mean operably connected or operably coupled. In various embodiments, the control component of the present disclosure may comprise a control component described in U.S. Patent Application No. 15 / 976,526, filed May 10, 2018, entitled "Control Component for Segmented Heating in an Aerosol Delivery Device," which is incorporated herein by reference in its entirety.

[0107] In various embodiments, the control component can also be configured to precisely control the amount of heat provided to the aerosol-generating components of the aerosol source member. While the heat required to volatilize a sufficient volume of the aerosol-generating components to provide the desired dose of inhalable substance per puff can vary for each particular substance used, it can be particularly useful to heat the heating component to a temperature of at least 120°C, at least 130°C, or at least 140°C. In some embodiments, preheating can occur at a temperature of at least 50°C, at least 75°C, at least 100°C, or at least 125°C. In some embodiments, the heating temperature can be at least 150°C, at least 200°C, at least 250°C, at least 300°C, or at least 350°C to volatilize an adequate amount of the aerosol-generating components and thus provide the desired dose of inhalable substance. However, it may be particularly desirable to avoid heating to temperatures substantially above about 550°C to avoid degradation and / or excessive premature volatilization of the aerosol-generating components. In particular, heating should be at a temperature low enough and for a period of time short enough to avoid significant combustion (preferably any combustion) of the aerosol-generating components. The present disclosure may provide components of the present articles in combinations and modes of use that produce a desired amount of inhalable substance at relatively low temperatures, among other things. Thus, yield may refer to one or both of aerosol generation within the article and delivery from the article to the consumer. In certain embodiments, the heating temperature can be from about 120°C to about 300°C, from about 130°C to about 290°C, from about 140°C to about 280°C, from about 150°C to about 250°C, or from about 160°C to about 200°C. As described in more detail below, the duration of heating can be controlled by several factors. As described further herein, the heating temperature and duration can depend on the desired volume of aerosol and ambient air desired to be drawn through the aerosol source member. However, the duration can vary depending on the heating rate of the heating element, as the article can be configured so that the heating element is energized only until the desired temperature is reached.Alternatively, the duration of heating can be correlated to the duration of a puff by the consumer using the article. Generally, the temperature and duration of heating (as well as the energization turns of the heater) are controlled by one or more components housed in a control body, as described above.

[0108] The amount of inhalable material emitted by the aerosol source member can vary based on the nature of the aerosol-forming components. Preferably, the aerosol source member is configured with a sufficient amount of aerosol-forming components, along with a sufficient amount of any aerosol-forming agents, to function at a sufficient temperature for a sufficient time to emit the desired amount over the course of use. The amount may be provided in a single inhalation from the aerosol source member, or may be divided into several puffs from the article over a relatively short period of time (e.g., less than 30 minutes, less than 20 minutes, less than 15 minutes, less than 10 minutes, or less than 5 minutes). For example, the device may provide an amount of nicotine per puff using the aerosol source member of about 0.01 mg to about 0.1 mg, about 0.05 mg to about 1.0 mg, about 0.08 mg to about 0.5 mg, about 0.1 mg to about 0.3 mg, or about 0.15 mg to about 0.25 mg. In other embodiments, the desired amount can be characterized in terms of the amount of wet total particulate matter delivered based on the duration and volume of the puff. For example, the aerosol source member may deliver at least 1.0 mg of wet total particulate matter per puff for a specified number of puffs (as described elsewhere herein) when smoked under standard FTC smoking conditions of a 2-second, 35 ml puff. Such testing may be performed using any standard smoking machine. In other embodiments, the amount of total particulate matter (TPM) produced under the same conditions for each puff may be at least 1.5 mg, at least 1.7 mg, at least 2.0 mg, at least 2.5 mg, at least 3.0 mg, between about 1.0 mg and about 5.0 mg, between about 1.5 mg and about 4.0 mg, between about 2.0 mg and about 4.0 mg, between about 2.0 mg and about 3.0 mg, between about 4.0 mg and about 6.0 mg, between about 6.0 mg and about 8.0 mg, or between about 8.0 mg and about 10.0 mg.

[0109] As mentioned above, the aerosol delivery device 400 of some embodiments may include a push button that can be coupled to a control component for manual control of the heating element. For example, in some embodiments, a consumer may energize the heating assembly 410 using a push button. Similar functionality associated with a push button may be achieved by other mechanical or non-mechanical means (e.g., magnetic or electromagnetic). Thus, activation of the heating assembly 410 can be controlled by a single push button. Alternatively, multiple push buttons may be provided to separately control various operations. In some embodiments, the one or more push buttons present can be located substantially flush with the casing of the first housing portion 402 and / or the second housing portion 404.

[0110] Instead of (or in addition to) any push button, the aerosol delivery device 400 of the present disclosure may include a component that energizes the heating assembly 410 in response to a consumer inhaling on an article (i.e., puff-activated heating). For example, the device may include a switch or flow sensor (not shown) within the first housing portion 402 and / or the second housing portion 404 and / or the mouthpiece 406 that is sensitive to either pressure or airflow changes when a consumer inhales on an article (i.e., puff-activated switch). Other suitable current activation / deactivation mechanisms may include a temperature-activated on / off switch or a lip-pressure-activated switch, or a touch sensor (e.g., a capacitance-based touch sensor) configured to sense contact between a user (e.g., the user's mouth or finger) and one or more surfaces of the aerosol delivery device 400. An exemplary mechanism capable of providing such puff-activation capability includes the Model 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc. of Freeport, Illinois. With such a sensor, pressure changes when a consumer inhales on the device can rapidly activate the heating assembly 410. Additionally, a flow-sensing device, such as one that uses the principles of hot wire anemometry, may be used to energize the heating assembly sufficiently quickly after sensing a change in airflow. Another puff-activated switch that can be used is a pressure differential switch, such as model number MPL-502-V, range A, manufactured by Micro Pneumatic Logic, Inc. of Fort Lauderdale, Florida. Another suitable puff-activated mechanism is a pressure-sensitive transducer (e.g., with an amplifier or gain stage) coupled to a comparator for detecting a predetermined threshold pressure. Yet another suitable puff-activated mechanism is a vane deflected by airflow, the movement of which is detected by a motion-sensing means. Yet another suitable activation mechanism is a piezoelectric switch. Also useful is a suitably connected Honeywell MicroSwitch Microbridge Airflow Sensor, part number AWM 2100V, manufactured by the MicroSwitch Division of Honeywell, Inc. of Freeport, Illinois.Additional examples of demand-operated electrical switches that may be used in heating circuits according to the present disclosure are described in U.S. Pat. No. 4,735,217 to Gerth et al., which is incorporated herein by reference in its entirety. Other suitable differential switches, analog pressure sensors, flow sensors, and the like will be apparent to those skilled in the art with the knowledge of this disclosure. In some embodiments, first housing portion 402 and / or second housing portion 404 may include a pressure-sensing tube or other passageway that provides a fluid connection between the puff-activated switch and the aerosol source member so that pressure changes during inhalation can be easily identified by the switch. Other exemplary smoke actuation devices useful in accordance with the present disclosure are disclosed in U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,874 to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., and U.S. Patent No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entireties. Reference is also made to the control scheme described in U.S. Patent No. 9,423,152 to Ampolini et al., which is incorporated herein by reference in its entirety.

[0111] In some embodiments, when a consumer inhales on the mouthpiece 406, the current actuation means can rapidly generate heat by ensuring that the flow of current through the heating assembly 410 is unrestricted or uninterrupted. For rapid heating, it can be useful to include a current regulation component to (i) regulate the flow of current through the heating element to control heating of the resistive element and the resulting temperature, and (ii) prevent overheating and degradation of the aerosol generation components. In some embodiments, the current regulation circuitry can be time-based. Specifically, such a circuitry can include a means for ensuring that the flow of current through the heating element is uninterrupted for an initial period during inhalation, followed by a timer means for regulating the current flow until inhalation is complete. For example, subsequent regulation can include rapid on / off switching of the current flow (e.g., on the order of about every 1-50 milliseconds) to maintain the heating element within a desired temperature range. Furthermore, regulation can include simply ensuring that the current flow is uninterrupted until the desired temperature is achieved, and then turning the current flow off completely. The heating element may be reactivated by the consumer initiating another puff on the item (or by manually activating a push button, depending on the particular switch embodiment used to activate the heater). Alternatively, subsequent adjustments may involve modulating the flow of current through the heating element to maintain the heating element within a desired temperature range. In some embodiments, the heating element may be energized for a duration of about 0.2 seconds to about 5.0 seconds, about 0.3 seconds to about 4.0 seconds, about 0.4 seconds to about 3.0 seconds, about 0.5 seconds to about 2.0 seconds, or about 0.6 seconds to about 1.5 seconds to emit a desired dose of inhalable substance. One exemplary time-based current regulation circuit may include a transistor, a timer, a comparator, and a capacitor. Suitable transistors, timers, comparators, and capacitors are commercially available and will be apparent to those skilled in the art.Exemplary timers are those available from NEC Electronics as C-1555C and from General Electric Intersil, Inc. as ICM7555, as well as so-called "555 timers" in various other sizes and configurations. An exemplary comparator is available from National Semiconductor as LM311. Additional description of such time-based current regulation circuits is provided in U.S. Patent No. 4,947,874 to Brooks et al., which is incorporated herein by reference in its entirety.

[0112] In some embodiments, the order in which the heaters are energized can be controlled by a control component, and corresponding data can be recorded so that if a user turns off the device (without replacing the aerosol source member), the user can later turn on the device and continue consuming the remaining portion of the aerosol source member. For example, if the first two heaters are energized and the corresponding portion of the aerosol source member is consumed by the consumer, the user may turn off the device, and when the user turns the device back on, the device will start with the third heater. Thus, in some embodiments, when the aerosol source member is removed from the device, the consumption status data for the aerosol source member may be reset. In some embodiments, individual heaters can be programmed to be energized for multiple puffs (e.g., 1 to 5 puffs, or more) before the next heater is energized. In various embodiments, such programming can be dependent on the total number of heaters, the consumable type and / or characteristics (e.g., mass, size, glycerol level, etc.). In light of the above, it can be appreciated that various mechanisms can be used to facilitate activation / deactivation of current to the heating member. For example, the device may include a timer for regulating the flow of current through the article (such as during inhalation by the consumer). The device may further include a timer-responsive switch for enabling and disabling the flow of current to the heating element. Regulating the flow of current may also comprise the use of a capacitor and components for charging and discharging the capacitor at a prescribed rate (e.g., a rate approximating the rate at which the heating element heats and cools). The flow of current may be regulated so that the flow of current through the heating element is uninterrupted, particularly for an initial period during inhalation, but the flow of current may be turned off or cycled alternately on and off after the initial period until inhalation is complete. Such cycles may be controlled by a timer capable of generating preset switching cycles, as described above. In certain embodiments, the timer may generate a periodic digital waveform.The flow during the initial period can be further regulated by using a comparator that compares a first voltage at the first input with a threshold voltage at the threshold input and generates an output signal when the first voltage equals the threshold voltage, thereby enabling the timer. Such an embodiment can further include a component for generating a threshold voltage at the threshold input and a component for generating the threshold voltage at the first input upon the elapse of the initial period.

[0113] Additional components are available for the aerosol delivery devices of the present disclosure. For example, U.S. Pat. No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouth end of a device that detects a user's lip movements associated with drawing and subsequently causes heating of the heating device; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow to a heat load array in response to a drop in pressure through a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. discloses a receptacle within a smoking device that includes an identifier that detects non-uniformities in the infrared transmittance of an inserted component and a controller that executes a detection routine when a component is inserted into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer et al. describes predefined, executable power cycles having multiple differential phases; and U.S. Pat. No. 5,934,289 to Watkins et al. discloses photonic-optronic components, U.S. Patent No. 5,954,979 to Counts et al. discloses means for varying the resistance to draw through a smoking device, U.S. Patent No. 6,803,545 to Blake et al. discloses certain battery configurations for use in smoking devices, U.S. Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices, U.S. Patent No. 8,402,976 to Fernando et al. discloses computer interface means for a smoking device to facilitate charging and enable computer control of the device, U.S. Patent No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device, and PCT Patent Application WO 2010 / 003480 to Flick discloses a fluid flow sensing system that indicates a puff using an aerosol generation system, all of the foregoing disclosures are incorporated herein by reference in their entireties. Another method uses electrical resistance changes to activate an aerosol delivery device and / or its heating assembly.It works by using a very thin, small metal probe in the form of a strip or wire that is attached perpendicular to the airflow within the cartridge. The airflow generated by the user exerts a mechanical force on the probe, bending it to some degree. This change in shape, which causes bending / tension on a portion of the probe, creates a change in the electrical resistance of the probe, and this change in resistance is sent as a pulse / information to the PCB, which acts as a trigger to activate the heating assembly 410.

[0114] Additional examples of components related to electronic aerosol delivery articles and disclosed materials or components that can be used in the present article include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513,253 to Kobayashi, U.S. Pat. No. 7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. No. 8,155,515 to Hon, and U.S. Pat. No. 6,155,515 to Hon. Nos. 6,944 and 8,375,957 to Thorens et al., U.S. Pat. No. 8,794,231 to Thorens et al., U.S. Pat. No. 8,851,083 to Oglesby et al., U.S. Pat. Nos. 8,915,254 and 8,925,555 to Monsees et al., U.S. Pat. No. 9,220,302 to DePiano et al., U.S. Patent Application Publication No. 2006 / 0196518 to Hon, and U.S. Pat. Examples of such aerosol delivery devices include U.S. Patent Application Publication No. 2009 / 0188490 to Oglesby et al., U.S. Patent Application Publication No. 2010 / 0024834 to Wang, U.S. Patent Application Publication No. 2010 / 0307518 to Wang, PCT Patent Application Publication No. WO 2010 / 091593 to Hon, and PCT Patent Application Publication No. WO 2013 / 089551 to Foo, each of which is incorporated herein by reference in its entirety. Furthermore, U.S. Patent Application No. 14 / 881,392 to Worm et al., filed October 13, 2015, discloses a capsule that can be included in an aerosol delivery device and a fob-shaped configuration for the aerosol delivery device, and is incorporated herein by reference in its entirety. In various embodiments, various materials disclosed by the aforementioned documents may be incorporated into the device, and all of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0115] As noted above, the electrical energy source used to power the various electrical components of device 400 can take a variety of forms. Preferably, the electrical energy source provides sufficient energy to rapidly heat the heating element in the manner described above and can power the device through use with multiple aerosol source elements 408 while still fitting conveniently into device 400. Examples of useful electrical energy sources include, preferably, rechargeable lithium-ion batteries (e.g., rechargeable lithium manganese dioxide batteries). In particular, lithium polymer batteries can be used because such batteries can improve safety. Other types of batteries, such as nickel-cadmium batteries, may also be used. Furthermore, preferred electrical energy sources are lightweight enough so as not to impair the desired smoking experience. Some examples of possible electrical energy sources are described in U.S. Pat. No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191 to Sur et al., filed October 21, 2015, the entire disclosures of each of which are incorporated herein by reference.

[0116] One example of an electrical energy source is the TKI-1550 rechargeable lithium-ion battery manufactured by Tadiran Batteries GmbH in Germany. In another embodiment, a useful electrical energy source may be an N50-AAA CADNICA nickel-cadmium battery manufactured by Sanyo Electric Company, Ltd. in Japan. In other embodiments, multiple such batteries, each providing 1.2 volts, may be connected in series. Other electrical energy sources, such as rechargeable lithium manganese dioxide batteries, may also be used. While any of these batteries or combinations thereof can be used for the electrical energy source, rechargeable batteries are preferred due to the cost and disposal considerations associated with disposable batteries. In embodiments in which a rechargeable battery is used, the aerosol delivery device 400 may further include charging contacts that interact with corresponding contacts in a standard 120-volt AC wall outlet or a conventional charging unit (not shown) that obtains power from another source, such as an automobile's electrical system or a separate portable power source. In further embodiments, the electrical energy source may also include a capacitor. Capacitors can discharge faster than batteries and can be charged between puffs, allowing the capacitor to discharge at a slower rate than if a battery were used to directly power the heating element. For example, a supercapacitor, such as an electric double layer capacitor (EDLC), may be used separately from or in combination with a battery. If used alone, the supercapacitor may be charged before each use of the device 400. Thus, the present disclosure may also include a charger component attachable to the device between uses to replenish the supercapacitor. In certain embodiments of the present disclosure, a thin-film battery may be used.

[0117] As noted above, in various embodiments, the aerosol delivery device 400 may include one or more indicators, such as indicator 412, which in the illustrated embodiment is located near the distal end of the first housing portion 402. In various embodiments, the one or more indicators can be located anywhere on the first housing portion 402 and / or the second housing portion 404 and / or the mouthpiece 406. In some embodiments, the indicators may comprise lights (e.g., single- or multi-color light-emitting diodes (LEDs)) that can provide indications of multiple aspects of the use of the device. For example, in some embodiments, a series of lights can correspond to the number of puffs on a given aerosol source member. Specifically, the lights may be illuminated sequentially with each puff, such that when all lights are illuminated, the consumer is notified that the aerosol source member has been consumed. Alternatively, all lights may be illuminated when the aerosol source member is inserted into the housing, and the lights may be extinguished with each puff, such that when all lights are extinguished, the consumer is notified that the aerosol source member has been consumed. In other embodiments, for example, each light may correspond to a respective heating element, and when the respective heating element reaches a puff threshold (e.g., 1-5 puffs, or more), the light may turn off, indicating that portion of the aerosol source member has been depleted. In yet other embodiments, only a single indicator may be present, whose illumination may indicate that current is flowing to the heating element and the device is actively heating. This may prevent consumers from unintentionally leaving the device in active heating mode. In alternative embodiments, one or more of the indicators may be components of the aerosol source member. While indicators are described above in connection with on / off visual indicators, other operational indicators are also encompassed. For example, visual indicators may also include changes in light color or intensity to indicate the progression of the smoking experience. Tactile and audible indicators are similarly encompassed by the present disclosure. Furthermore, combinations of such indicators may be used in a single device.

[0118] In various embodiments, the first housing portion 402 and / or the second housing portion 404 and / or the mouthpiece 406 can be formed from any material suitable for forming and maintaining a suitable structure, such as a tubular or rectangular shape, and for retaining an aerosol source member therein. In some embodiments, the housing can be formed from a single wall or multiple walls and from one or more materials (natural or synthetic) that are heat-resistant so as to maintain its structural integrity (e.g., not deteriorate) at least at temperatures that are the heating temperatures provided by the electric heating element, as further described herein. In some embodiments, heat-resistant polymers can be used. In other embodiments, ceramic materials can be used. In further embodiments, insulating materials can be used to prevent unnecessary heat transfer from the aerosol source element. When formed from a single layer, the housing can preferably have a thickness of about 0.1 mm to about 2 mm, about 0.2 mm to about 5.0 mm, about 0.5 mm to about 4.0 mm, about 0.5 mm to about 3.0 mm, or about 1.0 mm to about 3.0 mm. Additional exemplary types of components and materials that can be used to provide the above functionality or that can be used as substitutes for the above materials and components can be of the type described in U.S. Patent Application Publication No. 2010 / 00186757 to Crooks et al., U.S. Patent Application Publication No. 2010 / 00186757 to Crooks et al., and U.S. Patent Application Publication No. 2011 / 0041861 to Sebastian et al., the entire disclosures of which are incorporated herein by reference.

[0119] As shown in FIG. 9 , the illustrated embodiment includes a heating assembly 410 including a series of individual resistive heating elements 420 extending from a heating assembly frame 422. In various embodiments, a control component is configured to control the individual heating elements 420 independently and / or in any combination, and activation of the heating elements 420 is initiated using any of the methods described above. In the illustrated embodiment, each of the heating elements 420 is configured to heat a segment of the aerosol source member 408. The heating elements 420 in the illustrated embodiment comprise resistive heating elements and have a generally flat, rectangular shape, although in other embodiments, the heating elements 420 may have other shapes. The resistive heating elements may be configured to generate heat when an electric current is directed therethrough. Such heating elements often comprise a metallic material or an electrically conductive ceramic material and are configured to generate heat as a result of the electrical resistance associated with passing an electric current through them. In the illustrated embodiment, each of the heating elements includes heating element wires and / or traces 420 a (hereinafter referred to as “heating traces”) constructed from an electrically resistive material. Examples of electrically resistive materials include, but are not limited to, titanium, silver, nickel, nichrome, stainless steel, tungsten, indium tin oxide, various metal alloys, ceramics such as silicon carbide and silicon nitride, composite materials, and / or any combination thereof. In various embodiments, each heating trace 420 a can be secured on a body portion 420 b, which in the illustrated embodiment can be an extension or part of the heating assembly frame 422. In various embodiments, each heating trace 420 a can be formed on the corresponding body portion 420 b via printing, embedding, machining, melt casting, and other particle deposition techniques, such as chemical vapor deposition (CVD), physical vapor deposition (PVD), etc. In various embodiments, the heating assembly frame 422 and / or the body portion 420 b can be constructed from a metallic material (e.g., aluminum, stainless steel, a metal alloy, etc.).However, in other embodiments, the heating assembly frame 422 and / or the body 420b can be constructed from another material including, for example, a ceramic material (e.g., alumina, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, boron nitride, etc.), a polymeric material (e.g., polyimide, thermoplastic polyimide, polybenzimidazole, polyetheretherketone, polypropylene, high density polyethylene, etc.), a composite material, and / or any combination thereof.

[0120] 10 shows a perspective view of the aerosol source member 408 of FIG. 9 according to an exemplary embodiment of the present disclosure. In the illustrated embodiment, the aerosol source member 408 includes an aerosol generating component 430, an overwrap material 432, and a filter 434. As described in further detail below, when the aerosol source member 408 of the illustrated embodiment is attached to the second housing portion 404 of the aerosol delivery device 400, the filter 434 is positionable near the mouthpiece 406. In some embodiments, the aerosol source member 408 can be insertable and removable from the second housing portion 404, such as by removing the mouthpiece 406. In other embodiments, the second housing portion 404 and the aerosol source member 408 can be insertable and removable from the first housing portion 402.

[0121] As previously mentioned, the aerosol-generating component 430 of the illustrated embodiment can contain a solid or semi-solid material, which can be tobacco or a tobacco-derived material or a non-tobacco material. In various embodiments, such material can comprise tobacco-containing beads, shredded tobacco, shredded tobacco, reconstituted tobacco material, or a combination thereof, and / or a mixture of finely ground tobacco, tobacco extract, spray-dried tobacco extract, extruded tobacco, tobacco cast sheet, or other tobacco forms mixed with optional inorganic materials (such as calcium carbonate), optional flavoring and / or binders, and an aerosol-forming material, such as glycerol, to form a substantially solid or moldable (e.g., extrudable) substrate. Gels and suspensions are also available. Constructions and formulations of some representative types of solid and semi-solid aerosol-generating components are disclosed in U.S. Pat. No. 8,424,538 to Thomas et al., U.S. Pat. No. 8,464,726 to Sebastian et al., U.S. Pat. App. Pub. No. 2015 / 0083150 to Conner et al., U.S. Pat. App. Pub. No. 2015 / 0157052 to Ademe et al., and U.S. Pat. App. Pub. No. 2017-0000188 to Nordskog et al., filed June 30, 2015, all of which are incorporated herein by reference in their entireties.

[0122] As described above, in various embodiments, the aerosol-generating component may include an aerosol-generating component. The aerosol-generating component can be any material that, when heated, releases an inhalable substance, such as a flavor-containing substance. In the illustrated embodiment, the aerosol-generating component is a solid or semi-solid substrate containing the inhalable substance. The inhalable substance can specifically be a tobacco component or tobacco-derived material (i.e., a material naturally found in tobacco that can be isolated directly from tobacco, or a synthetically prepared material), or a non-tobacco material. For example, the aerosol-generating component may include a tobacco extract or fraction thereof combined with an inert substrate. The aerosol-generating component may further contain unburned tobacco or a composition containing unburned tobacco that releases an inhalable substance when heated to a temperature below combustion temperature. Less preferably, the aerosol-generating component may include tobacco condensate or a fraction thereof (i.e., the condensed component of smoke produced by tobacco combustion, leaving behind flavor and possibly nicotine).

[0123] In various embodiments, heating of the aerosol-generating component 430 may result in aerosolization of an aerosol precursor composition associated with the aerosol-generating component 430. In various embodiments, the filter 434 of the aerosol source member 408 can be configured to receive the generated aerosol therethrough in response to suction applied by a user to the mouthpiece 406 of the aerosol delivery device 400. Preferably, the elements of the aerosol-generating component 430 do not significantly thermally decompose (e.g., char, scorch, or burn), and the aerosolized components are entrained in air drawn through the aerosol delivery device 400, including the filter (if present), and into the user's mouth.

[0124] In one embodiment, the aerosol-generating component may contain a flavorful, aromatic tobacco blend in cut filler form. In another embodiment, the aerosol-generating component may contain reconstituted tobacco material, such as those described in U.S. Pat. Nos. 4,807,809 to Pryor et al., 4,889,143 to Pryor et al., and 5,025,814 to Raker, the entire disclosures of which are incorporated herein by reference. Furthermore, the reconstituted tobacco material may include reconstituted tobacco paper for cigarettes of the type described in "Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco," R.J. Reynolds Tobacco Company Monograph (1988), the entire contents of which are incorporated herein by reference. For example, the reconstituted tobacco material may include a sheet-like material containing tobacco and / or tobacco-related materials. Thus, in some embodiments, the aerosol-forming component may be formed from a wound roll of reconstituted tobacco material. In another embodiment, the substrate material may be formed from shreds, strips, or the like of reconstituted tobacco material. In another embodiment, the tobacco sheet may comprise a crimped sheet of reconstituted tobacco material. In some embodiments, the substrate material may comprise a superposed layer (e.g., a gathered web) that may or may not include a thermally conductive component. An example of an aerosol-forming component comprising a series of superposed layers (e.g., a gathered web) of an initial substrate sheet formed by a fibrous filler material, an aerosol-forming material, and a plurality of thermally conductive components is described in U.S. Patent Application No. 15 / 905,320, filed February 26, 2018, entitled "Heat Conducting Substrate For Electrically Heated Aerosol Delivery Device," which is incorporated herein by reference in its entirety.

[0125] In some embodiments, the aerosol-generating component 430 may contain a plurality of microcapsules, beads, granules, and / or the like, having tobacco-related material. For example, a typical microcapsule may be approximately spherical in shape and have an outer cover or shell containing a liquid center region of tobacco-derived extract and / or the like. In some embodiments, one or more of the substrate materials may contain a plurality of microcapsules, each formed in a hollow cylindrical shape. In some embodiments, one or more of the substrate materials may contain a binder material configured to maintain the structural shape and / or integrity of the plurality of microcapsules formed in a hollow cylindrical shape.

[0126] Tobacco materials useful in the present disclosure can vary and can include, for example, flue-cured, burley, Oriental or Maryland, dark, dark-flavored, and rustica tobaccos, as well as other rare or specialty tobaccos, or blends thereof. Tobacco materials can also include so-called "blends" and processed forms, such as processed tobacco stems (e.g., cut roll stems or cut puff stems), volume-expanded tobacco (e.g., puffed tobacco, advantageously in cut filler form, e.g., dry ice expanded tobacco (DIET)), and reconstituted tobacco (e.g., reconstituted tobacco produced using a paper-forming type process or a cast sheet type process). Various representative tobacco types, processed tobacco types, and tobacco blend types are described in U.S. Patent Nos. 4,836,224 to Lawson et al., 4,924,888 to Perfetti et al., 5,056,537 to Brown et al., 5,159,942 to Brinkley et al., 5,220,930 to Gentry, and 5,360,023 to Blakley et al., all of which are incorporated herein by reference. No. 6,701,936 to Shafer et al., U.S. Pat. No. 7,011,096 to Li et al., U.S. Pat. No. 7,017,585 to Li et al., U.S. Pat. No. 7,025,066 to Lawson et al., U.S. Patent Application Publication No. 2004-0255965 to Perfetti et al., PCT International Publication No. WO 02 / 37990 to Bereman, and Fund. Appl. Toxicol., 39, pp. 11-17 (1997). Additional exemplary tobacco compositions that may be useful in smoking devices, including those according to the present disclosure, are disclosed in U.S. Pat. No. 7,726,320 to Robinson et al., the entire contents of which are incorporated herein by reference.

[0127] Additionally, the aerosol-generating component may comprise an inert substrate into which an inhalable substance or its precursor is incorporated or otherwise deposited. For example, a liquid containing the inhalable substance may be coated onto, absorbed into, or adsorbed onto the inert substrate, such that upon application of heat, the inhalable substance is released in a form that can be drawn from the article of the present invention by application of positive or negative pressure. In some embodiments, the aerosol-generating component may contain a flavorful, aromatic tobacco blend in cut filler form. In another embodiment, the aerosol-generating component may contain reconstituted tobacco material, such as those described in U.S. Pat. Nos. 4,807,809 to Pryor et al., 4,889,143 to Pryor et al., and 5,025,814 to Raker, the entire disclosures of which are incorporated herein by reference.

[0128] In some embodiments, the aerosol-generating component may include tobacco, tobacco components and / or tobacco-derived materials and / or non-tobacco materials that have been processed, manufactured, produced and / or processed to incorporate an aerosol precursor composition (e.g., a humectant, e.g., propylene glycol, glycerin and / or the like) and / or at least one flavoring agent, and a flame retardant (e.g., diammonium phosphate and / or another salt) configured to help prevent ignition, thermal decomposition, combustion and / or charring of the aerosol delivery component by a heat source. Various modes and methods for incorporating tobacco into smoking articles, particularly smoking articles designed to intentionally prevent the combustion of substantially any tobacco within the smoking article, are described in U.S. Pat. No. 4,947,874 to Brooks et al., U.S. Pat. No. 7,647,932 to Cantrell et al., U.S. Pat. No. 8,079,371 to Robinson et al., U.S. Pat. No. 7,290,549 to Banerjee et al., and U.S. Patent Application Publication No. 2007 / 0215167 to Crooks et al., the entire disclosures of which are incorporated herein by reference.

[0129] In some embodiments, other flame-retardant / flame-retardant materials and additives can be included in the aerosol-generating component and may include organic phosphorus compounds, borax, hydrated alumina, graphite, potassium tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Others, such as nitrogen phosphonates, monoammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ethanolammonium borate, ammonium sulfamate, halogenated organic compounds, thiourea, and antimony oxide, may also be used. In each aspect of the flame-retardant, flame-retardant, and / or char-retardant materials used in the aerosol-generating component and / or other components (whether alone or in combination with each other and / or other materials), the desired properties are preferably provided without undesirable outgassing, chemical reactivity, or melt-type behavior. Additional flavors, flavorings, additives, and other possible enhancing ingredients are described in U.S. Patent Application Serial No. 15 / 707,461 to Phillips et al., incorporated herein by reference in its entirety.

[0130] In addition to the inhalable substance (e.g., generally a flavor, nicotine, or pharmaceutical), the aerosol-generating component may contain one or more aerosol- or vapor-forming materials, such as a polyhydric alcohol (e.g., glycerin, propylene glycol, or mixtures thereof) and / or water. Representative types of aerosol-forming materials are described in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al. and U.S. Pat. No. 5,101,839 to Jakob et al., PCT Publication No. WO 98 / 57556 to Biggs et al., and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, RJ Reynolds Tobacco Company Monograph (1988), all of which are incorporated herein by reference. Preferred aerosol-forming materials produce a visible aerosol when sufficient heat is applied to them, and highly preferred aerosol-forming materials produce an aerosol that can be considered "smoky." Additional tobacco materials, such as tobacco aroma oil, tobacco essence, spray-dried tobacco extract, freeze-dried tobacco extract, or tobacco dust, may be combined with the vapor-forming or aerosol-forming material. It should also be understood that the inhalable substance itself may be in a form that, upon heating, releases the inhalable substance as a vapor, an aerosol, or a combination thereof. In other embodiments, the inhalable substance need not necessarily be released in the form of a vapor or aerosol, but the vapor-forming or aerosol-forming material with which it may be combined may form a vapor or aerosol upon heating and essentially function as a carrier for the inhalable substance itself. Thus, the inhalable substance may be characterized as being coated on a substrate, absorbed into a substrate, adsorbed onto the surface of a substrate, or a natural component of the substrate (i.e., the material forming the substrate, e.g., tobacco or tobacco-derived material). Similarly, the aerosol-forming or vapor-forming material may be similarly characterized.In certain embodiments, the aerosol-generating component may specifically comprise a substrate containing an inhalable substance and a separate aerosol-forming material contained therein. Thus, during use, the substrate can be heated, and the aerosol-forming material can be volatilized into vapor form, entraining the inhalable substance therewith. In certain examples, the aerosol-generating component may comprise a solid substrate onto which a tobacco slurry and an aerosol-forming material and / or vapor-forming material are coated or absorbed or adsorbed. The substrate component may be any material that does not burn or otherwise degrade at the temperatures described herein, achieved by the heating element to facilitate release of the inhalable substance. For example, paper materials, including tobacco paper (e.g., paper-like materials containing tobacco fiber and / or reconstituted tobacco), may be used. Thus, in various embodiments, the aerosol-generating component can be characterized as comprising an inhalable substance; alternatively, comprising an inhalable substance and a separate aerosol- or vapor-forming agent; alternatively, comprising an inhalable substance and a substrate; or alternatively, comprising an aerosol-generating component, a separate aerosol- or vapor-forming agent, and a substrate. Thus, the substrate may contain an inhalable substance and one or both of an aerosol or vapor forming agent.

[0131] Optionally, the tobacco material or aerosol-forming component may further contain other ingredients, such as sugar, glycerin, vanilla, cocoa, licorice, and other flavoring materials, e.g., menthol. Exemplary plant-derived compositions that can be used are disclosed in U.S. Patent Application Publication No. 2012 / 0152265 to Dube et al. and U.S. Patent No. 9,107,453 to Dube et al. The selection of such additional ingredients can vary based on factors such as the sensory characteristics desired in the article, and the present disclosure is intended to encompass any such additional ingredients that would be readily apparent to one skilled in the art of tobacco and tobacco-related or tobacco-derived products. See, e.g., *Tobacco Flavoring Substances and Methods* by Gutcho, *Noyes Data Corp.* (1972) and *Tobacco Flavoring for Smoking Products* by Leffingwell et al. (1972).

[0132] The inhalable substance and / or the separate vapor-forming material can be provided on the aerosol-generating component in various configurations. For example, both materials can be associated with the aerosol-generating component such that the concentration of each material along the length of the aerosol-generating component is substantially constant (e.g., if the substrate is divided into multiple longitudinal segments, the total concentration of the material in each individual segment can be substantially similar, e.g., varying by less than 10%, less than 5%, or less than 2% by weight). In other embodiments, one or both of the materials can be present in a defined pattern. For example, the pattern can be a gradient in which the concentration continuously increases or decreases along the length of the substrate. In this way, the first puff with the article may provide a significantly greater or lesser amount of inhalable substance than the amount of inhalable substance in the last puff. The gradient can also be designed to provide a uniform production of inhalable substance throughout the entire puff. Furthermore, the pattern can be such that a large amount of inhalable substance is provided at a certain point along the length of the substrate (e.g., corresponding to the first puff with the article, the last puff, or some intermediate puff). In light of the present disclosure, any variety of such patterns can be envisioned, and such variations are also encompassed by the present disclosure. Such patterning can also be applied to additional ingredients (e.g., flavorings) described herein. For example, a large amount of flavoring can be provided on the substrate at a position substantially corresponding to the last puff or the last two or three puffs using the article. The release of such flavoring can notify the consumer that the last puff using the device is approaching or has been achieved. Various other configurations and components that can be included in the aerosol-generating components of the present disclosure are described in U.S. Patent No. 9,078,473 to Worm et al., the entire contents of which are incorporated herein by reference.

[0133] In some aspects of the present disclosure, the aerosol-generating component can be configured as an extruded material, as described in U.S. Patent Application Publication No. 2012 / 0042885 to Stone et al., which is incorporated herein by reference in its entirety. In still other aspects, the aerosol-generating component can be configured as an extruded structure and / or substrate that includes or consists essentially of tobacco, tobacco-related materials, glycerin, water, and / or binder materials, although certain formulations do not include binder materials. In various embodiments, the binder material can be any binder material commonly used in tobacco formulations, including, for example, carboxymethylcellulose (CMC), gums (e.g., guar gum), xanthan, pullulan, and / or alginate. According to some aspects, the binder material included in the aerosol delivery component can be configured to substantially maintain the structural shape and / or integrity of the aerosol delivery component. Various exemplary binders, binder properties, binder uses, and binder amounts are described in U.S. Patent No. 4,924,887 to Raker et al., which is incorporated herein by reference in its entirety.

[0134] In some embodiments, the aerosol-generating component can be further configured to substantially maintain its structure throughout the aerosol-generation process. That is, the aerosol-generating component is configured to substantially maintain its shape throughout the aerosol-generation process (i.e., the aerosol delivery component does not continuously deform under applied shear stress). In some embodiments, the aerosol-generating component may contain liquid and / or some moisture content, but in some embodiments, the aerosol-generating component is configured to remain substantially solid throughout the aerosol-generation process and substantially maintain its structural integrity throughout the aerosol-generation process. Exemplary tobacco and / or tobacco-related materials suitable for substantially solid aerosol delivery components are described in U.S. Patent Application Publication No. 2015 / 0157052 to Ademe et al., U.S. Patent Application Publication No. 2015 / 0335070 to Sears et al., U.S. Patent No. 6,204,287 to White, and U.S. Patent No. 5,060,676 to Hearn et al., each of which is incorporated herein by reference in its entirety.

[0135] In yet another embodiment, the aerosol-generating component may comprise an extruded structure and / or substrate formed from marumerized and / or non-marumerized tobacco. Marumerized tobacco is known, for example, from U.S. Patent No. 5,105,831 to Banerjee et al., which is incorporated herein by reference in its entirety. Marumerized tobacco contains about 20 to about 50 percent (by weight) of a tobacco blend in powder form, along with glycerol (about 20 to about 30 percent by weight), calcium carbonate (typically about 10 to about 60 percent by weight, often about 40 to about 60 percent by weight), and a binder and / or flavoring agent as described herein.

[0136] In various embodiments, the aerosol-generating component wall can be formed substantially from a material that can naturally contain an inhalable substance therein (e.g., cigarette paper), or can be formed from any additional material (e.g., paper) that can have an inhalable substance and / or vapor-forming or aerosol-forming agent incorporated therein. In addition to the inhalable substance and / or vapor-forming or aerosol-forming substance, the substrate wall may contain additional components. For example, a vapor barrier can be included on the outer surface of the aerosol-generating component wall. Preferably, the vapor barrier is disposed on the wall surface adjacent to (or in contact with) the heating element when the aerosol-generating component is heated. In certain embodiments, the vapor barrier can be formed from an electrically insulating material or can include a layer of electrically insulating material that can contact the heating element. For example, a metal foil can be used as the vapor barrier, and the foil can have an insulating layer (e.g., a metal oxide layer) in contact with the heating element to prevent vapor or aerosol release into the outer volume of the aerosol-generating component and facilitate vapor or aerosol release into the annular space defined by the inner surface of the aerosol-generating component wall. Any vapor barrier material may be used, such as metal foil.

[0137] In further embodiments, the aerosol-generating component can be formed from a material that softens or changes phase (particularly from solid to molten) at about the operating temperature of the article. For example, the aerosol-generating component can be a wax or gel, and the inhalable substance can be incorporated therein. In such embodiments, it can be particularly useful to include a vapor barrier (or similar material) that provides support to the aerosol-generating component and substantially prevents the aerosol-generating component from contacting the heating element. Similarly, the aerosol-generating component can include a vapor barrier layer coated with the inhalable substance and / or aerosol-forming material. For example, one or more of such coating materials can be in a microencapsulated form that preferably releases its components at temperatures within one or more of the operating ranges described elsewhere herein. Microencapsulation techniques that can be useful in such embodiments are disclosed, for example, in U.S. Patent No. 4,464,434 to Davis.

[0138] In some embodiments, the aerosol-generating component may include tobacco components (e.g., reconstituted cast tobacco sheets or tobacco beads) or non-tobacco components (e.g., herbs, paper, cellulose, etc.) including one or more of a binder component, a humectant component, a flavor component, a humectant component, and a casing material. In some embodiments, the binder component may contain, for example, cellulose and / or guar gum. In some embodiments, the humectant component may contain, for example, about 15-25% glycerol, about 14.5% sorbitol, and / or about 3-10% propylene glycol. In some embodiments, the flavor component may contain, for example, acetic acid, citric acid, acetoin, lactic acid, menthol, peppermint oil, carob extract, cocoa products, licorice extract, invert sugar, and / or sucrose. In some embodiments, the humectant component may contain, for example, about 15-25% water.

[0139] In the illustrated embodiment, the aerosol-generating component 430, or a portion thereof, is encased within an overwrap material 432. In the illustrated embodiment, the overwrap material comprises an aluminum laminate. However, in other embodiments, the overwrap material may be different. In some embodiments, the overwrap material can be formed from a thermally conductive material and / or any material useful for providing additional structure and / or support to the aerosol source member. In various embodiments, the overwrap material may include a material that resists heat transfer (or promotes heat transfer), which may include paper or other fibrous material, e.g., a cellulosic material. The overwrap material may also include at least one filler material embedded or dispersed within the fibrous material. In various embodiments, the filler material may have the form of water-insoluble particles. Additionally, the filler material may incorporate inorganic components. In various embodiments, the overwrap may be formed from multiple layers, such as an underlying bulk layer and an overlying layer, such as a paper wrapper typical of cigarettes. Such materials may include, for example, lightweight "rag fibers" such as flax, hemp, sisal, rice straw, and / or esparto. Additional description regarding the construction of overwrap materials that may be used with the present disclosure may be found in U.S. Pat. No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety. In additional embodiments, the overwrap material may have one or more of the following properties: it may be impermeable to aerosol migration, it may have the ability to withstand elevated temperatures of interest, it may promote radial heat transfer from the heater to the tobacco stick material, it may resist axial heat transfer along the tobacco stick, away from the heated segment, and / or it may have a relatively low thermal mass so as not to inhibit the rapid temperature rise of the heated segment. In one embodiment, the overwrap material may be stainless steel foil, which in some embodiments may be approximately 0.001 inches thick.

[0140] As mentioned above, in the illustrated embodiment, the aerosol source member 408 includes a filter 434. In various embodiments, the filter can be made from a variety of materials, including, for example, cellulose acetate, polylactic acid, and / or polypropylene materials. In various embodiments, the filter may enhance the structural integrity of the aerosol source member and / or provide optional filtration capabilities and / or resistance to suction. For example, articles according to the present disclosure can exhibit a pressure drop of about 50 to about 250 mm of water at an airflow of 17.5 cc / sec. In further embodiments, the pressure drop can be about 60 mm to about 180 mm or about 70 mm to about 150 mm. Pressure drop values ​​can be measured using a Filtrona Filter Test Station (CTS Series) available from Filtrona Instruments and Automation Ltd. or a Quality Test Module (QTM) available from Cerulean Division of Molins, PLC. The length of the filter at the mouth end of the aerosol source member can vary, such as from about 2 mm to about 20 mm, from about 5 mm to about 20 mm, or from about 10 mm to about 15 mm. In some embodiments, the filter may be separate from the overwrap, while in other embodiments, the filter may be held in place by the overwrap.

[0141] Additional exemplary types of overwrap materials, packaging components, and treated packaging materials that can be used in the overwraps of the present disclosure are described in U.S. Pat. No. 5,105,838 to White et al., U.S. Pat. No. 5,271,419 to Arzonico et al., U.S. Pat. No. 5,220,930 to Gentry, U.S. Pat. No. 6,908,874 to Woodhead et al., U.S. Pat. No. 6,929,013 to Ashcraft et al., U.S. Pat. No. 7,195,019 to Hancock et al., U.S. Pat. No. 7,276,120 to Holmes, U.S. Pat. No. 7,275,548 to Hancock et al., PCT Publication No. WO 01 / 08514 to Fournier et al., and PCT Publication No. WO 03 / 043450 to Hajaligol et al., which are incorporated by reference herein in their entireties. Representative packaging materials are commercially available from Schweitzer-Maudit International as RJ Reynolds Tobacco Company grades 119, 170, 419, 453, 454, 456, 465, 466, 490, 525, 535, 557, 652, 664, 672, 676, and 680. The porosity of the packaging material can vary, frequently from about 5 CORESTA units to about 30,000 CORESTA units, often from about 10 CORESTA units to about 90 CORESTA units, and frequently from about 8 CORESTA units to about 80 CORESTA units.

[0142] To maximize delivery of aerosol and flavors that might otherwise be diluted by radial (i.e., outward) air penetration through the overwrap, one or more layers of non-porous cigarette paper may be used to encase the aerosol source member (with or without the overwrap present). Examples of suitable non-porous cigarette paper are commercially available from Kimberly-Clark Corp. as KC-63-5, P878-5, P878-16-2, and 780-63-5. Preferably, the overwrap is a material that is substantially impermeable to vapors formed during use of the article of the present invention. Optionally, the overwrap can comprise a resilient paperboard material, foil-backed paperboard, metal, polymeric material, or the like, which can be surrounded by a wrap of cigarette paper. The overwrap can include tipping paper that encloses the components and, optionally, can be used to attach a filter material to the aerosol source member, as described elsewhere herein. In various embodiments, other components may be present between the aerosol-generating component and the mouth end of the aerosol source member, and the mouth end may include a filter. For example, in some embodiments, one or any combination of the following may be disposed between the aerosol-generating component and the mouth end: an air gap; a phase-change material for cooling the air; a flavor-releasing medium; ion-exchange fibers capable of selective chemical adsorption; aerogel particles as a filter medium; and other suitable materials.

[0143] The overall length of the overwrap, if present, can vary from substantially the same as the length of the aerosol-generating component to approximately twice the length of the aerosol-generating component. Thus, the aerosol-generating component may have a length that is up to about 50%, up to about 30%, or up to about 10% shorter than the length of the overwrap. Preferably, the aerosol-generating component may have a length that is at least 10%, at least 15%, or at least 20% shorter than the length of the overwrap. More specifically, the distance that the overwrap extends beyond the aerosol-generating component may be about 5%, 10%, 15%, 20%, 25%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 100% of the length of the aerosol-generating component.

[0144] 11 shows a perspective exploded view of an aerosol source member 500 according to an exemplary embodiment of the present disclosure. In particular, the aerosol delivery device 500 of the illustrated embodiment includes a first housing portion 502, a second housing portion 504, a mouthpiece 506, an aerosol source member 508 (in the form of a cartridge containing liquid or semi-liquid aerosol generating components), a heating assembly 510, and an indicator 512. The aerosol delivery device 500 further includes an electrical energy source (not visible, e.g., a battery, which may be rechargeable, and / or a rechargeable supercapacitor) and a control component (not visible, e.g., a microprocessor, either separately or as part of a microcontroller, a printed circuit board (PCB) including the microprocessor and / or microcontroller, etc.). As described in further detail below, the heating assembly 510 of various embodiments comprises a series of independent and separate heating elements, each configured to heat a segment of the aerosol source member 508.

[0145] In various embodiments, one or both of the control component and the electrical energy source can be coupled with first housing portion 502. For purposes of this application, the phrase "coupled" when used with respect to one component as compared to another component may encompass embodiments in which one component is disposed within another component and / or embodiments in which one component is separate but otherwise operably connected to another component. For example, in the illustrated embodiment, both the control component and the electrical energy source are disposed within first housing portion 502. However, in other embodiments, one or both of the control component and the electrical energy source can be disposed in different components. Additional information regarding the control component and the electrical energy source is provided below.

[0146] In various embodiments, the first housing portion 502 and the second housing portion 504 can be mechanically engaged together in various ways. For example, in some embodiments, the first housing portion 502 and the second housing portion 504 can engage via a threaded connection. In other embodiments, the first housing portion 502 and the second housing portion 504 can engage via an interference fit or a friction fit. In other embodiments, the first housing portion 502 and the second housing portion 504 can engage via a magnetic connection. In other embodiments, the first housing portion 502 and the second housing portion 504 can engage via a snap-fit ​​connection. In still other embodiments, the first housing portion 502 and the second housing portion 504 can engage via a bayonet-style connection including a male component (e.g., a pin) and a female component (e.g., an L-shaped slot). Note that in some embodiments, the first housing portion 502 and the second housing portion 504 can comprise a single, integral housing portion.

[0147] Although other embodiments may vary, in the illustrated embodiment, the aerosol source member 508 is inserted into the second housing portion 504 by removing the mouthpiece 506 and inserting the aerosol source member 508 so that it is positioned adjacent to the heating assembly 510. In various embodiments, one or both of the second housing portion 504 or the aerosol source member 508 may be keyed or may include one or more stops or positioning features to aid in proper positioning of the aerosol source member 508. In the illustrated embodiment, there is a single series of heating elements 520 extending from the heating assembly frame 522 such that the single series of heating elements 520 is configured to be positioned on one side of the aerosol source member 508. However, in other embodiments, there may be two or more series of heating elements 520 configured to be positioned on both sides of the aerosol source member 508. After insertion of the aerosol source member 508, the mouthpiece can then be reinserted into the second housing portion 504. In various embodiments, the mouthpiece can be attached to the second attachment portion in a variety of different ways, including, for example, via a press-fit attachment, a threaded attachment, a hinged attachment, a magnetic attachment, etc. In various embodiments, the first housing portion 502, the second housing 504, and / or the mouthpiece 506 can be detachable from one another, and thus any one or all can be interchangeable.

[0148] In some embodiments, the first housing portion 502 and / or the second housing portion 504 may also include one or more push buttons configured to activate certain operations of the device 500, such as, for example, turning on the device and initiating heating of the heating assembly 510 (e.g., one or more heating elements of the heating assembly). As described in further detail below, in various embodiments, the aerosol source member 508 may comprise an aerosol-generating component configured to be disposed near the heating assembly 510. It should be noted that although the first housing portion 502, the second housing portion 504, and the aerosol source member 508 in the illustrated embodiment have a generally elongated, rectangular, cuboid shape, in other embodiments, the first housing portion 502, the second housing portion 504, and / or the aerosol source member 508 may have any other shape, including, for example, the shape of a traditional cigarette or cigar.

[0149] In certain embodiments, the first housing portion 502, the second housing portion 504, and / or the aerosol source member 508 may be referred to as disposable or reusable. For example, the electrical energy source and / or the housing portion 502 containing the electrical energy source may comprise a replaceable or rechargeable battery, a solid-state battery, a thin-film solid-state battery, a rechargeable supercapacitor, etc., and thus may be combined with any type of charging technology, including connection to a wall charger, a connection to an automobile charger (i.e., cigarette lighter socket), a connection to a computer via a Universal Serial Bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), etc., a connection to a photovoltaic cell (sometimes called a solar cell) or solar panel, a wireless charger, such as a charger using inductive wireless charging (e.g., including wireless charging compliant with the Qi wireless charging standard by the Wireless Power Consortium (WPC)), or a radio frequency (RF)-based charger. An example of an inductive wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is incorporated herein by reference in its entirety. Additionally, in some embodiments, the aerosol source member 508 and / or the second housing portion 504 containing the aerosol source member 508, and / or the mouthpiece 506 may comprise a disposable device. Disposable components for use with the control body are disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0150] In various embodiments, the control component may include control circuitry (connectable to additional components, as further described herein) that may be connected to a source of electrical energy by conductive wires. In various embodiments, the control component may control when and how the heating assembly 510 (e.g., one or more heating elements) receives electrical energy to heat the aerosol-generating component to release an inhalable substance for inhalation by the consumer. Such control may relate to the actuation of a pressure-sensitive switch, or the like, described in further detail below. Note that the terms “connected” or “coupled” should not be interpreted as requiring a direct connection without intervening components. Rather, these terms may encompass a direct connection and / or a connection via one or more intervening components. Thus, in various embodiments, these terms will be understood to mean operably connected or operably coupled. In various embodiments, the control component of the present disclosure may comprise a control component described in U.S. Patent Application No. 15 / 976,526, filed May 10, 2018, entitled "Control Component for Segmented Heating in an Aerosol Delivery Device," which is incorporated herein by reference in its entirety.

[0151] In various embodiments, the control component may also be configured to precisely control the amount of heat provided to the aerosol-generating components of the aerosol source member. While the heat required to volatilize a sufficient volume of the aerosol-generating components to provide the desired dose of inhalable substance per puff may vary for each specific substance used, it may be particularly useful to heat the heating component to a temperature of at least 120°C, at least 130°C, or at least 140°C. In some embodiments, the heating temperature may be at least 150°C, at least 200°C, at least 300°C, or at least 350°C to volatilize an adequate amount of the aerosol-generating components and thus provide the desired dose of inhalable substance. However, it may be particularly desirable to avoid heating to temperatures substantially above about 550°C to avoid degradation and / or excessive premature volatilization of the aerosol-generating components. The present disclosure may provide components of the present article in combinations and modes of use that produce the desired amount of inhalable substance at relatively low temperatures. Thus, yield may refer to one or both of aerosol generation within the article and delivery from the article to the consumer. In certain embodiments, the heating temperature can be about 120°C to about 300°C, about 130°C to about 290°C, about 140°C to about 280°C, about 150°C to about 250°C, or about 160°C to about 200°C. As described in more detail below, the duration of heating can be controlled by several factors. As described further herein, the heating temperature and duration can depend on the desired volume of aerosol and ambient air desired to be drawn through the aerosol source member. However, the duration can vary depending on the heating rate of the heating element, since the article can be configured so that the heating element is energized only until the desired temperature is reached. Alternatively, the duration of heating can be tied to the duration of a puff taken by a consumer using the article. Generally, the temperature and duration of heating are controlled by one or more components housed in a control body, as described above.

[0152] The amount of inhalable material emitted by the aerosol source member can vary based on the nature of the aerosol-forming components. Preferably, the aerosol source member is configured with a sufficient amount of aerosol-forming components, along with a sufficient amount of any aerosol-forming agents, to function at a sufficient temperature for a sufficient time to emit the desired amount over the course of use. The amount may be provided in a single inhalation from the aerosol source member, or may be divided up to be provided through several puffs from the article over a relatively short period of time (e.g., less than 30 minutes, less than 20 minutes, less than 15 minutes, less than 10 minutes, or less than 5 minutes). For example, the device may provide an amount of nicotine per puff using the aerosol source member of about 0.01 mg to about 0.10 mg, about 0.05 mg to about 1.0 mg, about 0.08 mg to about 0.5 mg, about 0.1 mg to about 0.3 mg, or about 0.15 mg to about 0.25 mg. In other embodiments, the desired amount can be characterized in terms of the amount of wet total particulate matter delivered based on the duration and volume of the puff. For example, the aerosol source member may deliver at least 1.0 mg of wet total particulate matter per puff for a specified number of puffs (as described elsewhere herein) when smoked under standard FTC smoking conditions of a 2-second, 35 ml puff. Such testing can be performed using any standard smoking machine. In other embodiments, the amount of total particulate matter (TPM) produced under the same conditions for each puff can be at least 1.5 mg, at least 1.7 mg, at least 2.0 mg, at least 2.5 mg, at least 3.0 mg, between about 1.0 mg and about 5.0 mg, between about 1.5 mg and about 4.0 mg, between about 2.0 mg and about 4.0 mg, between about 2.0 mg and about 3.0 mg, between about 4.0 mg and about 6.0 mg, between about 6.0 mg and about 8.0 mg, or between about 8.0 mg and about 10.0 mg.

[0153] As mentioned above, the aerosol delivery device 500 of some embodiments may include a push button that can be coupled to a control component for manual control of the heating element. For example, in some embodiments, a consumer may energize the heating assembly 510 using the push button. Similar functionality associated with the push button may be achieved by other mechanical or non-mechanical means (e.g., magnetic or electromagnetic). Thus, activation of the heating assembly 510 can be controlled by a single push button. Alternatively, multiple push buttons may be provided to separately control various operations. In some embodiments, the one or more push buttons present may be located substantially flush with the casing of the first housing portion 502 and / or the second housing portion 504.

[0154] Instead of (or in addition to) any push button, the aerosol delivery device 500 of the present disclosure may include a component that energizes the heating assembly 510 in response to a consumer inhaling on an article (i.e., puff-activated heating). For example, the device may include a switch or flow sensor (not shown) within the first housing portion 502 and / or the second housing portion 504 and / or the mouthpiece 506 that is sensitive to either pressure or airflow changes when a consumer inhales on an article (i.e., puff-activated switch). Other suitable current activation / deactivation mechanisms may include a temperature-activated on / off switch or a lip-pressure-activated switch, or a touch sensor (e.g., a capacitance-based touch sensor) configured to sense contact between a user (e.g., the user's mouth or finger) and one or more surfaces of the aerosol delivery device 500. An exemplary mechanism capable of providing such puff-activation capability includes the Model 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc. of Freeport, Illinois. Such a sensor allows the heating assembly 510 to be rapidly activated by changes in pressure when a consumer inhales on the device. Additionally, a flow-sensing device, such as one using the principles of hot wire anemometry, may be used to energize the heating assembly sufficiently quickly after sensing a change in airflow. Another puff-activated switch that can be used is a pressure differential switch, such as model number MPL-502-V, range A, manufactured by Micro Pneumatic Logic, Inc., Fort Lauderdale, Florida. Another suitable puff-activated mechanism is a pressure-sensitive transducer (e.g., with an amplifier or gain stage) coupled to a comparator for detecting a predetermined threshold pressure. Yet another suitable puff-activated mechanism is a vane deflected by airflow, the movement of which is detected by a motion-sensing means. Yet another suitable activation mechanism is a piezoelectric switch. Also useful is a suitably connected Honeywell MicroSwitch Microbridge Airflow Sensor, part number AWM 2100V, manufactured by the MicroSwitch Division of Honeywell, Inc., Freeport, Illinois.Additional examples of demand-operated electrical switches that may be used in heating circuits according to the present disclosure are described in U.S. Pat. No. 4,735,217 to Gerth et al., which is incorporated herein by reference in its entirety. Other suitable differential switches, analog pressure sensors, flow sensors, or the like will be apparent to those skilled in the art with the knowledge of this disclosure. In some embodiments, first housing portion 502 and / or second housing portion 504 may include a pressure-sensing tube or other passageway that provides a fluid connection between the puff-activated switch and the aerosol source member so that pressure changes during inhalation can be easily identified by the switch. Other exemplary smoke actuation devices useful in accordance with the present disclosure are disclosed in U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,874 to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., and U.S. Patent No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entireties. Reference is also made to the control scheme described in U.S. Patent No. 9,423,152 to Ampolini et al., which is incorporated herein by reference in its entirety.

[0155] In some embodiments, when a consumer inhales on the mouthpiece 506, the current actuation means can rapidly generate heat by ensuring that the current through the heating assembly 510 is not limited or interrupted. For rapid heating, it can be useful to include a current regulation component to (i) regulate the flow of current through the heating element to control heating of the resistive element and the resulting temperature, and (ii) prevent overheating and degradation of the aerosol generation components. In some embodiments, the current regulation circuitry can be time-based. Specifically, such a circuitry may include means for ensuring that the current through the heating element is not interrupted for an initial period during inhalation, followed by a timer means for regulating the current flow until inhalation is complete. For example, subsequent regulation may include rapid on / off switching of the current flow (e.g., on the order of about every 1-50 milliseconds) to maintain the heating element within a desired temperature range. Furthermore, regulation may simply involve ensuring that the current flow is not interrupted until the desired temperature is achieved, and then turning the current flow off completely. The heating element may be reactivated by the consumer initiating another puff on the item (or by manually activating a push button, depending on the particular switch embodiment used to activate the heater). Alternatively, subsequent adjustments may involve modulating the flow of current through the heating element to maintain the heating element within a desired temperature range. In some embodiments, the heating element may be energized for a duration of about 0.2 seconds to about 5.0 seconds, about 0.3 seconds to about 4.0 seconds, about 0.4 seconds to about 3.0 seconds, about 0.5 seconds to about 2.0 seconds, or about 0.6 seconds to about 1.5 seconds to emit a desired dose of inhalable substance. One exemplary time-based current regulation circuit may include a transistor, a timer, a comparator, and a capacitor. Suitable transistors, timers, comparators, and capacitors are commercially available and will be apparent to those skilled in the art. Exemplary timers are those available from NEC Electronics as C-1555C and from General Electric Intersil, Inc. as ICM7555, as well as other so-called "555 timers" in various sizes and configurations.An exemplary comparator is available from National Semiconductor as LM311. Additional description of such time-based current regulation circuits is provided in U.S. Patent No. 4,947,874 to Brooks et al., which is incorporated herein by reference in its entirety.

[0156] In light of the above, it can be appreciated that various mechanisms can be used to facilitate activation / deactivation of current to the heating element. For example, the device may include a timer for regulating the flow of current through the article (such as during inhalation by the consumer). The device may further include a timer-responsive switch for enabling and disabling the flow of current to the heating element. Regulating the flow of current can also include the use of a capacitor and components for charging and discharging the capacitor at a prescribed rate (e.g., a rate approximating the rate at which the heating element heats and cools). The flow of current may be regulated so that the flow of current through the heating element is uninterrupted, particularly for an initial period during inhalation, but the flow of current may be turned off or cycled alternately on and off after the initial period until inhalation is completed. Such cycles can be controlled by a timer capable of generating preset switching cycles, as described above. In certain embodiments, the timer can generate a periodic digital waveform. The flow during the initial period can be further regulated by using a comparator that compares a first voltage at the first input with a threshold voltage at the threshold input and generates an output signal when the first voltage equals the threshold voltage, thereby enabling the timer. Such an embodiment can further include a component for generating a threshold voltage at the threshold input and a component for generating the threshold voltage at the first input upon the elapse of the initial period.

[0157] Additional components may be utilized in the aerosol delivery devices of the present disclosure. For example, U.S. Pat. No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouth end of a device that detects a user's lip movements associated with drawing and subsequently causes heating of the heating device; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow to a heating load array in response to a drop in pressure through a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. discloses a receptacle within a smoking device that includes an identifier that detects non-uniformities in infrared transmittance of an inserted component and a controller that executes a detection routine when a component is inserted into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer et al. describes predefined, executable power cycles having multiple differential phases; U.S. Pat. No. 5,934,289 to Watkins et al. discloses photonic-optronic components, U.S. Patent No. 5,954,979 to Counts et al. discloses means for varying the resistance to draw through a smoking device, U.S. Patent No. 6,803,545 to Blake et al. discloses certain battery configurations for use in smoking devices, U.S. Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices, U.S. Patent No. 8,402,976 to Fernando et al. discloses computer interface means for a smoking device to facilitate charging and enable computer control of the device, U.S. Patent No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device, and PCT Patent Application WO 2010 / 003480 to Flick discloses a fluid flow sensing system that indicates a puff using an aerosol generation system, all of the foregoing disclosures are incorporated herein by reference in their entireties. Another method uses electrical resistance changes to activate an aerosol delivery device and / or its heating assembly.It works by using a very thin, small metal probe in the form of a strip or wire that is attached perpendicular to the airflow within the cartridge. The airflow generated by the user exerts a mechanical force on the probe, bending it to some degree. This change in shape, which causes bending / tension on a portion of the probe, creates a change in the electrical resistance of the probe, and this change in resistance is sent as a pulse / information to the PCB, which acts as a trigger to activate the heating assembly 510.

[0158] Additional examples of components related to electronic aerosol delivery articles and disclosed materials or components that may be used in the present article include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513,253 to Kobayashi, U.S. Pat. No. 7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. No. 8,155,515 to Hon, and U.S. Pat. No. 6,155,515 to Hon. Nos. 6,944 and 8,375,957 to Thorens et al., U.S. Pat. No. 8,794,231 to Thorens et al., U.S. Pat. No. 8,851,083 to Oglesby et al., U.S. Pat. Nos. 8,915,254 and 8,925,555 to Monsees et al., U.S. Pat. No. 9,220,302 to DePiano et al., U.S. Patent Application Publication No. 2006 / 0196518 to Hon, and U.S. Pat. Examples of such aerosol delivery devices include U.S. Patent Application Publication No. 2009 / 0188490 to Oglesby et al., U.S. Patent Application Publication No. 2010 / 0024834 to Wang, U.S. Patent Application Publication No. 2010 / 0307518 to Wang, PCT Patent Application Publication No. WO 2010 / 091593 to Hon, and PCT Patent Application Publication No. WO 2013 / 089551 to Foo, each of which is incorporated herein by reference in its entirety. Furthermore, U.S. Patent Application No. 14 / 881,392 to Worm et al., filed October 13, 2015, discloses a capsule that can be included in an aerosol delivery device and a fob-shaped configuration for the aerosol delivery device, and is incorporated herein by reference in its entirety. In various embodiments, various materials disclosed by the aforementioned documents may be incorporated into the device, and all of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0159] As noted above, the electrical energy source used to power the various electrical components of device 500 can take a variety of forms. Preferably, the electrical energy source provides sufficient energy to rapidly heat the heating element in the manner described above and can power the device through use with multiple aerosol source elements 508 while still fitting conveniently into device 500. Examples of useful electrical energy sources include, preferably, rechargeable lithium-ion batteries (e.g., rechargeable lithium manganese dioxide batteries). Lithium polymer batteries, in particular, can be used because such batteries can improve safety. Other types of batteries, such as nickel-cadmium batteries, may also be used. Furthermore, preferred electrical energy sources are lightweight enough so as not to impair the desired smoking experience. Some examples of possible electrical energy sources are described in U.S. Pat. No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191 to Sur et al., filed October 21, 2015, the entire disclosures of each of which are incorporated herein by reference.

[0160] One example of an electrical energy source is the TKI-1550 rechargeable lithium-ion battery manufactured by Tadiran Batteries GmbH in Germany. In another embodiment, a useful electrical energy source may be an N50-AAA CADNICA nickel-cadmium battery manufactured by Sanyo Electric Company, Ltd. in Japan. In other embodiments, multiple such batteries, each providing 1.2 volts, may be connected in series. Other electrical energy sources, such as rechargeable lithium manganese dioxide batteries, may also be used. While any of these batteries or combinations thereof can be used for the electrical energy source, rechargeable batteries are preferred due to the cost and disposal associated with disposable batteries. In embodiments in which a rechargeable battery is used, the aerosol delivery device 500 may further include charging contacts that interact with corresponding contacts in a standard 120-volt AC wall outlet or a conventional charging unit (not shown) that obtains power from another source, such as a vehicle's electrical system or a separate portable power source. In further embodiments, the electrical energy source may also include a capacitor. Capacitors can discharge faster than batteries and can be charged between puffs, allowing the capacitor to discharge at a slower rate than if a battery were used to directly power the heating element. For example, a supercapacitor, such as an electric double layer capacitor (EDLC), may be used separately from or in combination with a battery. If used alone, the supercapacitor may be charged before each use of the device 500. Thus, the present disclosure may also include a charger component that can be attached to the device between uses to replenish the supercapacitor. In certain embodiments of the present disclosure, a thin-film battery may be used.

[0161] As noted above, in various embodiments, the aerosol delivery device 500 may include one or more indicators, such as indicator 512, which in the illustrated embodiment is located near the distal end of the first housing portion 502. In various embodiments, the one or more indicators can be located anywhere on the first housing portion 502 and / or the second housing portion 504 and / or the mouthpiece 506. In some embodiments, the indicators may include lights (e.g., single- or multi-color light-emitting diodes (LEDs)) that can provide indications of multiple aspects of the device's use. For example, in some embodiments, a series of lights may correspond to the number of puffs on a given aerosol source member. Specifically, the lights may be illuminated sequentially with each puff, such that when all lights are illuminated, the consumer is notified that the aerosol source member has been consumed. Alternatively, all lights may be illuminated when the aerosol source member is inserted into the housing, and the lights may be extinguished with each puff, such that when all lights are extinguished, the consumer is notified that the aerosol source member has been consumed. In yet other embodiments, there may be only a single indicator, the illumination of which may indicate that current is flowing through the heating element and that the device is actively heating. This may prevent a consumer from unintentionally leaving the device in active heating mode. In alternative embodiments, one or more of the indicators may be components of the aerosol source element. While the indicators are described above in connection with visual indicators of an on / off method, other indicators of operation are also encompassed. For example, visual indicators may also include changes in light color or intensity to indicate the progression of the smoking experience. Tactile and audible indicators are also encompassed by the present disclosure. Furthermore, a combination of such indicators may be used in a single device.

[0162] In various embodiments, the first housing portion 502 and / or the second housing portion 504 and / or the mouthpiece 506 can be formed from any material suitable for forming and maintaining a suitable structure, such as a tubular or rectangular shape, and for retaining an aerosol source member therein. In some embodiments, the housing can be formed from a single wall or multiple walls and from one or more materials (natural or synthetic) that are heat-resistant so as to maintain its structural integrity (e.g., not deteriorate) at least at temperatures that are the heating temperatures provided by the electric heating element, as further described herein. In some embodiments, heat-resistant polymers can be used. In other embodiments, ceramic materials can be used. In further embodiments, insulating materials can be used to prevent unnecessary heat transfer from the aerosol source element. When formed from a single layer, the housing can preferably have a thickness of about 0.2 mm to about 5.0 mm, about 0.5 mm to about 4.0 mm, about 0.5 mm to about 3.0 mm, or about 1.0 mm to about 3.0 mm. Additional exemplary types of components and materials that may be used to provide the above-described functions or that may be used as substitutes for the above-described materials and components may be of the type described in U.S. Patent Application Publication No. 2010 / 00186757 to Crooks et al., U.S. Patent Application Publication No. 2010 / 00186757 to Crooks et al., and U.S. Patent Application Publication No. 2011 / 0041861 to Sebastian et al., the entire disclosures of which are incorporated herein by reference.

[0163] As shown in FIG. 11 , the illustrated embodiment includes a heating assembly 510 that includes a series of individual resistive heating elements 520 extending from a heating assembly frame 522. In the illustrated embodiment, there are six individual heating elements 520. However, in other embodiments, there may be any number of heating elements, including, for example, as few as one or more than six heating elements, such as, for example, 16 heating elements. In various embodiments, a control component is configured to control the individual heating elements 520 independently and / or in any combination, and activation of the heating elements 520 is initiated using any of the methods described above. In the illustrated embodiment, each of the heating elements 520 is configured to heat a segment of the aerosol source member 508. The heating elements 520 in the illustrated embodiment comprise resistive heating elements and have a generally flat, rectangular shape, although in other embodiments, the heating elements 520 may have other shapes. The resistive heating elements may be configured to generate heat when an electric current is directed therethrough. Such heating elements often comprise a metallic material and are configured to generate heat as a result of the electrical resistance associated with passing an electric current through them. In the illustrated embodiment, each of the heating elements includes a heating element wire and / or trace 520a (hereinafter referred to as a "heat trace") constructed from an electrically resistive material. Examples of electrically resistive materials include, but are not limited to, titanium, silver, nickel, nichrome, stainless steel, various metal alloys, ceramics such as silicon carbide and silicon nitride, composite materials, and / or any combination thereof. In various embodiments, each heating trace 520a can be secured onto a body portion 520b, which in the illustrated embodiment can be an extension or part of the heating assembly frame 522. In various embodiments, each heating trace 520a can be created on a corresponding body portion 520b via printing, embedding, machining, squeegee casting, etc. In various embodiments, the heating assembly frame 522 and / or the body portion 520b can be constructed from a metallic material (e.g., aluminum, stainless steel, a metal alloy, etc.).However, in other embodiments, the heating assembly frame 522 and / or the body 520b can be constructed from another material including, for example, a ceramic material (e.g., alumina, silica, mullite, silicon carbide, silicon nitride, aluminum nitride, etc.), a polymeric material (e.g., polyimide, thermoplastic polyimide, polybenzimidazole, polyetheretherketone, polypropylene, high density polyethylene, etc.), a composite material, and / or any combination thereof.

[0164] FIG. 12 shows a perspective view of an aerosol source member 508 in the form of a reservoir cartridge, according to an exemplary embodiment of the present disclosure. In various embodiments, the aerosol source member 508 includes a reservoir housing 540, a reservoir 542, and a series of atomizer chambers 544, each containing a liquid transport element 546. As described in further detail below, the series of atomizer chambers 544 are configured to substantially align with the series of heating elements 520 of the heating assembly 510. In various embodiments, the reservoir housing 540 can be constructed from one or more of a variety of materials, including, for example, a metallic material, a ceramic material, a glass material, and / or a plastic material, such as, for example, an acrylic material (e.g., polymethyl methacrylate). In some embodiments, the reservoir housing 540 may comprise a translucent or transparent material to allow a user to see the amount of aerosol-generating component remaining therein. In the illustrated embodiment, the reservoir housing 540 is constructed from polypropylene or Tritan™, although other materials are possible in other embodiments.

[0165] In various embodiments, reservoir 542 may hold aerosol-generating components, which may be in the form of a liquid or semi-liquid aerosol precursor composition. Some representative types of aerosol precursor components and formulations are also described and characterized in U.S. Pat. No. 7,726,320 to Robinson et al., U.S. Pat. No. 8,881,737 to Collett et al., and U.S. Pat. No. 9,254,002 to Chong et al., U.S. Pat. Publication No. 2013 / 0008457 to Zheng et al., U.S. Pat. Publication No. 2015 / 0020823 to Lipowicz et al., and U.S. Pat. Publication No. 2015 / 0020830 to Koller, the entire disclosures of which are incorporated herein by reference, and WO 2014 / 182736 to Bowen et al. Other aerosol precursors that can be used include those incorporated into VUSE® products from RJ Reynolds Vapor Company, BLU™ products from Fontem Ventures BV, MISTIC MENTHOL products from Mistic Ecigs, MARK TEN products from Nu Mark LLC, JUUL products from Juul Labs, Inc., and VYPE products from British American Tobacco. Also desirable are so-called "smoke juices" for e-cigarettes available from Johnson Creek Enterprises LLC.Further examples of aerosol precursor compositions are sold under the trade names BLACK NOTE, COSMIC FOG, THE MILKMAN E-LIQUID, FIVE PAWNS, THE VAPOR CHEF, VAPE WILD, BOOSTED, THE STEAM FACTORY, MECH SAUCE, CASEY JONES MAINLINE RESERVE, MITTEN VAPORS, DR. CRIMMY'S V-LIQUID, SMILEY E LIQUID, BEANTOWN VAPOR, CUTTWOOD, CYCLOPS VAPOR, SICBOY, GOOD LIFE VAPOR, TELEOS, PINUP VAPORS, SPACE JAM, MT. BAKER VAPOR, and JIMMY THE JUICE MAN. Embodiments of foamable materials can be used with the aerosol precursor compositions, such as those described in U.S. Patent Application Publication No. 2012 / 0055494 to Hunt et al., which is incorporated herein by reference in its entirety. Further, the use of foamable materials is described in, for example, U.S. Pat. No. 4,639,368 to Niazi et al., U.S. Pat. No. 5,178,878 to Wehling et al., U.S. Pat. No. 5,223,264 to Wehling et al., U.S. Pat. No. 6,974,590 to Pather et al., U.S. Pat. No. 7,381,667 to Bergquist et al., U.S. Pat. No. 8,424,541 to Crawford et al., U.S. Pat. No. 8,627,828 to Strickland et al., and U.S. Pat. No. 9,307,787 to Sun et al., as well as U.S. Patent Application Publication No. 2010 / 0018539 to Brinkley et al. and PCT Publication No. WO 97 / 06786 to Johnson et al., all of which are incorporated herein by reference in their entireties. Additional description of embodiments of aerosol precursor compositions, including descriptions of tobacco or tobacco-derived components contained in the aerosol precursor compositions, is provided in U.S. Patent Application Nos. 15 / 216,582 and 15 / 216,590, both to Davis et al., filed July 21, 2016, and incorporated herein by reference in their entireties.

[0166] The reservoir housing 540 may include an aerosol channel 548 that extends from one end of the reservoir housing 540 to the other end of the reservoir housing 540. Notably, in some embodiments, the aerosol channel 548 extends from the distal end of the reservoir housing 540 to the end of the aerosol housing 540 that is proximate the mouthpiece 506 when the aerosol source member 508 is inserted into the second housing portion 504. In various embodiments, the aerosol channel 548 may comprise a groove or slot in the reservoir housing 540 that traverses each of the nebulizer chambers 544. In this manner, when a user inhales on the aerosol delivery device 500, the drawn-in air passes through the nebulizer channel 544, allowing any aerosol generated in one or more of the nebulizer chambers 544 to be retrieved.

[0167] In the illustrated embodiment, the aerosol source member 508 includes six atomizer chambers 544 (and thus six liquid transport elements 546). In various embodiments, the liquid transport elements 546 may comprise porous monoliths. For example, in the illustrated embodiment, the liquid transport elements 546 may comprise ceramic materials such that the aerosol precursor composition delivered to the liquid transport elements 546 can be absorbed therein for aerosolization. In other embodiments, the liquid transport elements may comprise other materials, including, for example, cotton, silica, cellulose, and other fibrous materials. While the size and shape of the atomizer chambers can vary in various embodiments, in the illustrated embodiment, the atomizer chambers 544 have a generally semi-cylindrical shape, and each liquid transport element 546 extends from one end of the atomizer chamber 544 to the other in a substantially vertical direction and slightly below the aerosol channel 548. In particular, the end of each liquid transport element 546 penetrates the reservoir housing 540, such that the liquid transport element 546 is in fluid contact with the aerosol precursor composition contained in the reservoir 542, causing the aerosol precursor composition to flow into the liquid transport element 546 (e.g., via capillary action).

[0168] An electrical connection between the control component and the heating assembly 510 allows the control component to direct electrical current to the heating assembly 510 upon activation by a user (e.g., via a button) and / or when a puff using the aerosol delivery device is detected. As described above, the aerosol delivery device 500 of the illustrated embodiment includes a mouthpiece 506. When a user draws on the mouthpiece 506, air 550 can be directed from the environment through one or more air intakes in the device 500 and to the distal end of the aerosol channel 548. In some embodiments, the air 550 may enter the device 500 through one or more openings in the first housing portion 502 and / or the second housing portion 504. In some embodiments, the air 550 may additionally or alternatively enter through an opening between the first housing portion 502 and the second housing portion 504. Other possible entry openings are described in U.S. Pat. No. 9,220,302 to DePiano et al., which is incorporated herein by reference in its entirety.

[0169] In some embodiments, a sensor (e.g., a flow sensor) within the aerosol delivery device 500 may detect a puff. When a puff is detected, the control component may direct an electric current to one or more of the heating elements 520. One or more of the heating elements 520 may therefore vaporize an aerosol precursor composition contained in one or more liquid transport elements 546 disposed near the activated heating elements 520. As air 550 enters the nebulizer chamber 544, the air 550 travels through (and / or around) the liquid transport elements 546. At such time, if the respective heating elements 520 are activated, the air 550 mixes with the vaporized aerosol precursor composition and becomes an aerosol 552.

[0170] Air drawn into aerosol channel 548 may be drawn through each of the nebulizer chambers 544, resulting in air 550 exiting through the opposite end of aerosol channel 548 and through the mouthpiece 506 of device 500. As shown, for example, if only the third heating element 520 is activated, the drawn air 550 mixes with the aerosol formed in the third nebulizer chamber 544. Thus, for example, if multiple heating elements 520 are activated, the air 550 will pick up aerosol from multiple nebulizer chambers 544.

[0171] In some embodiments, at least a portion of the reservoir 542 may comprise multiple layers of nonwoven fibers. Thus, for example, a liquid component can be adsorbed and retained within the reservoir 542. In various embodiments, the reservoir 542 is fluidly connected to a series of spray chambers 544. Thus, each liquid transport element 546 can be configured to transport liquid from the reservoir 542 adjacent to a corresponding one of the plurality of heating elements 520 via capillary action or other liquid transport mechanism.

[0172] In the illustrated embodiment, the reservoir 542 comprises a single reservoir compartment in which all of the liquid transport elements 546 are in contact with the same liquid composition. However, in other embodiments, there can be two or more separate reservoir compartments, each of which may contain one or more of the atomizer chambers. For example, in some embodiments, the reservoir 542 may include two or more separate reservoir compartments that are sealingly independent of one another. Thus, for example, some atomizer chambers may be separate from one another so that some of the liquid transport elements 546 are not in contact with the same liquid composition. For example, in some embodiments in which there are six atomizer chambers, there may be two, three, four, five, or six separate reservoir chambers, each of which may contain a different liquid composition. As an example, one or more of the separate reservoir compartments may contain different aerosol precursor compositions and / or different flavorants, thereby allowing a user to select from one or more aerosol precursor compositions and / or flavorants as desired. In other embodiments, separate subreservoirs containing different substances for contributing to or adding to the vapor generated by the device may be heated. For example, one subreservoir may contain a nicotine-containing liquid and another subreservoir may contain a flavorant (e.g., selectable from multiple subreservoirs containing flavorants), and the nicotine-containing liquid and flavorant are added to the vapor generated by the device. In another example, two subreservoirs may be heated simultaneously to create a two-component reaction in the generated vapor. For example, a subreservoir containing an acidic liquid (e.g., lactic acid) may be heated and combined with a subreservoir containing a nicotine liquid to form a nicotine salt in the vapor. Because the number of possible separate heating elements and / or reservoir compartments can be varied, in some embodiments, a user may choose from among a nearly infinite number of combinations of aerosol precursor compositions and / or aerosol precursor composition flavorants.

[0173] As used herein, reference to a "flavoring agent" refers to a compound or component that can be aerosolized and delivered to a user and that provides a sensory experience in terms of taste and / or aroma. Exemplary flavoring agents include, but are not limited to, 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, rosemary, hibiscus, rosehip, yerba mate, guayusa, honeybush, rooibos, yerba santa, bacopa monniera, ginkgo, ashwagandha, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, and flavors and flavor packages of the type and characteristics conventionally used in cigarette, cigar, and pipe tobacco flavorings. Also, syrups such as high fructose corn syrup can be used. Exemplary plant-derived compositions that may be suitable are disclosed in U.S. Patent No. 9,107,453 to Dube et al. and U.S. Patent Application Publication No. 2012 / 0152265, both of which are incorporated herein by reference in their entireties. 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 that would be readily apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See, for example, Gutcho's *Tobacco Flavoring Substances and Methods*, Noyes Data Corp. (1972) and Leffingwell et al.'s *Tobacco Flavoring for Smoking Products* (1972), the entire disclosures of which are incorporated herein by reference. It should be noted that reference to flavoring should not be limited to any single flavoring, such as those listed above, and may, in fact, refer to a combination of one or more flavorings.

[0174] Some possible components that can be included in an aerosol source member cartridge are described, for example, in U.S. Patent Application Publication No. 2014 / 0261495 to DePiano et al., which is incorporated herein by reference in its entirety. Additional components that can be included in an aerosol source member cartridge, and related details, are described, for example, in U.S. Patent Application Publication No. 2015 / 0335071 to Brinkley et al., filed May 23, 2014, which is incorporated herein by reference in its entirety. Various components that can be applied to an aerosol delivery device according to the present disclosure can be selected from components described in the art and commercially available. See, for example, U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al., which is incorporated herein by reference in its entirety, for a reservoir and heater system for controllable delivery of multiple aerosolizable materials in an electronic smoking article.

[0175] For any of the above embodiments, the overall functionality of the device can vary based on the requirements of a particular application. In one embodiment, for example, once the aerosol source member is inserted into the device and the heating assembly is in the heated (e.g., closed) position, the device can be initially activated using a switch and / or push button as described above. Preheating can occur next and occur over approximately 20-30 seconds. During the preheating period, a specific current / voltage passed through the heating assembly (e.g., heating element) can cause the temperature of the heating element to reach approximately 100-120°C. A temperature sensor (e.g., a resistance temperature detector) can be included to control the preheating temperature to ensure it does not exceed the desired preheating temperature.

[0176] After preheating is complete, individual heating elements can be activated, which in some embodiments can be triggered by the user by drawing air into the device. In some embodiments, the temperature of the heating elements may peak at 250-350°C during each draw. Some embodiments may include a pressure sensor to measure pressure changes within the device and activate one or more heating elements with each air draw. The device may further be configured so that power can be switched / controllable between elements via a control component using one or more stimuli. For example, in some embodiments, the stimuli may be related to the number of puffs and / or other parameters, such as, for example, the temperature change of the heating elements.

[0177] In some embodiments, the heating element may be energized after a preheating period caused by the first draw on the device. The heating element may be energized again for the second and third draws on the device. The number of times each heating element is energized can be adjusted depending on the total number of heating elements, the resistance and size of the heating elements, and the power of the heating elements. After the segment of the aerosol generating component associated with a heating element is consumed, another heating element, such as the next heating element, becomes active. In some embodiments, the device can be configured so that the power to subsequent heating elements is controllable each time the user turns on the device. In some embodiments, the heating cycle can be reset to zero and start over after energizing the last heating element in the series and / or when the aerosol source member is removed or inserted into the device by the user. Additional functional features that may be applicable to the present aerosol delivery device are described in U.S. Patent Application No. 15 / 976,526, filed May 10, 2018, entitled "Control Component for Segmented Heating in an Aerosol Delivery Device," which is incorporated herein by reference in its entirety.

[0178] It should be noted that for any of the above aerosol delivery devices, the device can be configured to accommodate aerosol source members having solid or semi-solid aerosol-generating components (e.g., similar to aerosol source member 408), or aerosol source members having liquid or semi-liquid aerosol-generating components (e.g., similar to aerosol source member 508). As such, the control components of that particular device can be configured to adjust or control various parameters (e.g., heating temperature, heating time, etc.) to accommodate the particular aerosol-generating components used with the device.

[0179] Although the various figures described herein show the housing or housing portion and the aerosol source member in an operative relationship, it should be understood that the housing or housing portion and the aerosol source member may exist as separate devices, and therefore any description provided elsewhere herein regarding combined components should be understood as applying to the control body and the aerosol source member as separate and distinct components.

[0180] In another aspect, the present disclosure may be directed to a kit providing various components described herein. For example, the kit may include a housing or one or more housing portions having one or more aerosol source members. The kit may further include a housing or one or more housing portions having one or more charging components. The kit may further include a housing or one or more housing portions having one or more batteries. The kit may further include a housing or one or more housing portions having one or more aerosol source members and one or more charging components and / or one or more batteries. In further embodiments, the kit may include multiple aerosol source members. The kit may further include multiple aerosol source members and one or more batteries and / or one or more charging components. In the above embodiments, the aerosol source members or the housing or housing portions may be provided with a heating assembly included therein. The kits of the present invention may further include a case (or other packaging, transport, or storage component) for housing one or more of the additional kit components. The case can be a reusable hard or soft container. Furthermore, the case can simply be a box or other packaging structure.

[0181] Many modifications and other embodiments of the present disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the present disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. a control body having an outer housing; a source of electrical energy disposed within the housing; a control component operably connected to a source of electrical energy; a heating assembly operably connected to the control component; an aerosol source member including an aerosol-generating component configured to be positioned proximate to the heating assembly; 1. An aerosol delivery device comprising: An aerosol delivery device, wherein the heating assembly comprises a series of heating elements, each heating element being independent and distinct and configured to heat a segment of the aerosol source element.

2. 2. The aerosol delivery device of claim 1, wherein the heating assembly comprises a movable jaw and a fixed jaw, the heating element is disposed on the movable jaw, and the movable jaw is configured to move between an open position in which the movable jaw is spaced from the fixed jaw and the heating element is not in contact with the aerosol source element, and a closed position in which the series of heating elements of the movable jaw are in contact with the aerosol source element.

3. 3. The aerosol delivery device of claim 2, further comprising a receiving sleeve configured to receive the aerosol source member, the receiving sleeve being disposed between the movable jaw and the fixed jaw in the closed position.

4. 3. The aerosol delivery device of claim 2, wherein the series of heating members comprises a series of heating pins configured to penetrate the aerosol source member in the closed position and to create electrical connections with a series of corresponding connectors arranged on the fixed jaw.

5. 5. The aerosol delivery device of claim 4, wherein the heating pin has a generally cylindrical shape.

6. 3. The aerosol delivery device of claim 2, wherein the series of heating members comprises individual heating elements configured to extend into the aerosol source member in the closed position.

7. 7. The aerosol delivery device of claim 6, wherein the heating element has a generally blade-like shape.

8. 3. The aerosol delivery device of claim 2, wherein the movable jaw is configured to be automatically movable.

9. 3. The aerosol delivery device of claim 2, wherein the movable jaw is configured to be manually movable.

10. 2. The aerosol delivery device of claim 1, wherein the series of heating elements comprises a series of individual heating elements, the heating assembly comprises two or more movable jaws, one or more of the heating elements is disposed on each movable jaw, and the movable jaws are configured to move between an open position in which the movable jaws are spaced apart from each other and the heating elements are not in contact with the aerosol source member, and a closed position in which the series of heating elements of each movable jaw are in contact with the aerosol source member.

11. 11. The aerosol delivery device of claim 10, wherein the heating assembly comprises three movable jaws, the heating elements of each movable jaw having a staggered configuration relative to the other movable jaws.

12. 11. The aerosol delivery device of claim 10, wherein the heating element is configured to extend into the aerosol source member in the closed position.

13. 11. The aerosol delivery device of claim 10, wherein the movable jaw is configured to be automatically movable.

14. 11. The aerosol delivery device of claim 10, wherein the movable jaw is configured to be manually movable.

15. 10. The aerosol delivery device of claim 1, wherein the heating assembly comprises a series of stationary heating elements positioned adjacent to the aerosol source member.

16. 16. The aerosol delivery device of claim 15, wherein the aerosol source member comprises a removable cartridge and the aerosol-generating component contains tobacco or a tobacco-derived material.

17. 16. The aerosol delivery device of claim 15, wherein the aerosol source member comprises a removable cartridge and the aerosol generating component contains a liquid aerosol precursor composition.

18. 18. The aerosol delivery device of claim 17, wherein the cartridge defines a series of nebulizer chambers and a separate wick extends through each nebulizer chamber.

19. 20. The aerosol delivery device of claim 18, wherein each of the fixed heating elements is configured to be positioned adjacent a corresponding nebulizer chamber.

20. 10. The aerosol delivery device of claim 1, wherein the heating members are configured to be independently controllable.

Images