Aerosol delivery device with conductive insert

Abstract

This disclosure provides an aerosol delivery device. [Solution] The aerosol delivery device 100 comprises an aerosol source member 200 having a base material that defines an outer surface and an internal region and has an aerosol precursor composition bonded thereto; a control body 102 having a housing 104 configured to receive the aerosol source member; an electrical energy source 108 coupled to the housing; and a heating assembly 110 operably connected to the electrical energy source. The heating assembly includes a plurality of spikes that can be configured to articulate between a retracted position in which the plurality of spikes are not in contact with the aerosol source member and a heating position in which the plurality of spikes penetrate the outer surface of the base material and enter a portion of its internal region.

Description

Technical Field

[0001] The present disclosure relates to aerosol delivery articles and their use for generating tobacco components or other materials in an inhalable form. More specifically, the present disclosure relates to an aerosol delivery device that uses electrical heating to heat tobacco or non-tobacco materials, preferably without significant combustion, to provide a substance that can be inhaled in the form of an aerosol for human consumption.

Background Art

[0002] As improved or alternative smoking products based on the combustion of tobacco, many smoking products have been proposed over the years. Exemplary alternatives include devices in which a solid fuel or a liquid fuel is burned to transfer heat to the tobacco or in which a chemical reaction is used to provide such a heat source. An example is the smoking product described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0003] The focus of improved or alternative smoking products has typically been to provide the sensation associated with smoking a cigarette, cigar, or pipe without delivering a substantial amount of incomplete combustion and pyrolysis products. To this end, numerous smoking products, flavor generators, and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials or to provide the sensation of smoking a cigarette, cigar, or pipe without significantly burning the tobacco. See, for example, the various alternative smoking products, aerosol delivery devices, and heat sources described in the background art of Robinson et al., U.S. Patent No. 7,726,320, 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 in their entirety herein by reference. See also, for example, the various types of smoking products, aerosol delivery devices and electric heating sources referenced by the trademark names and commercial suppliers described in Bless et al.'s U.S. Patent Application Publication No. 2015 / 0220232, which is incorporated herein by reference in its entirety. Additional types of smoking products, aerosol delivery devices and electric heating sources referenced by the trademark names and commercial suppliers are described in DePiano et al.'s U.S. Patent Application Publication No. 2015 / 0245659, which is also incorporated herein by reference in its entirety.Other representative cigarettes or smoking products described and, in some cases, commercially available, are incorporated herein by reference in their entirety by U.S. Patent No. 4,735,217 by Gerth et al., U.S. Patent No. 4,922,901 by Brooks et al., U.S. Patent No. 4,947,874 and U.S. Patent No. 4,947,875 by Counts et al., U.S. Patent No. 5,060,671 by Counts et al., U.S. Patent No. 5,249,586 by Morgan et al., and U.S. Patent No. 5,249,586 by Counts et al. Japanese Patent No. 5,388,594, U.S. Patent No. 5,666,977 by Higgins et al., U.S. Patent No. 6,053,176 by Adams et al., U.S. Patent No. 6,164,287 by White, U.S. Patent No. 6,196,218 by Voges, U.S. Patent No. 6,810,883 by Felter et al., U.S. Patent No. 6,854,461 by Nichols, U.S. Patent No. 7,832,410 by Hon, U.S. Patent No. 7,513 by Kobayashi U.S. Patent No. 253, Robinson et al.'s U.S. Patent No. 7,726,320, Hamano's U.S. Patent No. 7,896,006, Shayan's U.S. Patent No. 6,772,756, Hon's U.S. Patent Application Publication No. 2009 / 0095311, Hon's U.S. Patent Application Publication No. 2006 / 0196518, U.S. Patent Application Publication No. 2009 / 0126745 and U.S. Patent Application Publication No. 2009 / 0188490, Thorens et al.'s U.S. Patent Application This includes the specifications described in Publication No. 2009 / 0272379, the specifications of Monsees et al., Publication Nos. 2009 / 0260641 and 2009 / 0260642, the specifications of Oglesby et al., Publication Nos. 2008 / 0149118 and 2010 / 0024834, the specifications of Wang, Publication No. 2010 / 0307518, and Hon, PCT International Publication No. 2010 / 091593.

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

[0005] [Patent Document 1] U.S. Patent No. 9,078,473 [Patent Document 2] U.S. Patent No. 7,726,320 [Patent Document 3] U.S. Patent Application Publication No. 2013 / 0255702 [Patent Document 4] U.S. Patent Application Publication No. 2014 / 0096781 [Patent Document 5] U.S. Patent Application Publication No. 2015 / 0220232 Specification [Patent Document 6] U.S. 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] U.S. Patent Application Publication No. 2009 / 0095311 [Patent Document 25] U.S. Patent Application Publication No. 2006 / 0196518 [Patent Document 26] U.S. Patent Application Publication No. 2009 / 0126745 [Patent Document 27] U.S. Patent Application Publication No. 2009 / 0188490 [Patent Document 28] U.S. Patent Application Publication No. 2009 / 0272379 [Patent Document 29] U.S. Patent Application Publication No. 2009 / 0260641 [Patent Document 30] U.S. Patent Application Publication No. 2009 / 0260642 [Patent Document 31] U.S. Patent Application Publication No. 2008 / 0149118 [Patent Document 32] U.S. Patent Application Publication No. 2010 / 0024834 [Patent Document 33] U.S. Patent Application Publication No. 2010 / 0307518 [Patent Document 34] International Publication No. 2010 / 091593 [Summary of the Invention] [Problems to be Solved by the Invention]

[0006] Articles that produce the taste and sensation of smoking by electrically heating tobacco, tobacco-derived materials, or other plant-derived materials have historically suffered from inconsistent performance characteristics. For example, some articles have exhibited inconsistent release of flavors or other inhalable materials. Therefore, it may be desirable to provide smoking products that can provide the smoking sensation of a cigarette, cigar, or pipe without burning the base material, without requiring a combustion heat source, and with improved performance characteristics. [Means for solving the problem]

[0007] In various embodiments, this disclosure provides aerosol delivery devices. This disclosure includes, but is not limited to, the following exemplary embodiments.

[0008] Exemplary Embodiment 1: An aerosol delivery device comprising: an aerosol source member comprising a base material having an aerosol precursor composition defined and bound to an outer surface and an internal region; a control body having a housing configured to receive the aerosol source member; an electrical energy source coupled to the housing; and a heating assembly operably connected to the electrical energy source, wherein the heating assembly comprises a plurality of spikes, the plurality of spikes configured to articulate between a retracted position in which the plurality of spikes are not in contact with the aerosol source member and a heating position in which the plurality of spikes penetrate the outer surface of the base material and enter a portion of its internal region.

[0009] Exemplary Embodiment 2: An aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein the outer surface of the substrate material includes a plurality of separated conductive bands.

[0010] Exemplary Embodiment 3: An aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein each of the separated conductive bands surrounds the entire outer surface of the substrate material.

[0011] Exemplary Embodiment 4: Aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein each of the separated conductive bands extends around a limited portion of the outer surface of the substrate material and has a first end and a second end that can be defined.

[0012] Exemplary Embodiment 5: Aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein, at the heating position, each spike of a plurality of heat-conducting spikes is in contact with the first and second ends of a separated conductive band.

[0013] Exemplary Embodiment 6: Aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein a plurality of spikes constitute a heating member of a heating assembly.

[0014] Exemplary Embodiment 7: Aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein a plurality of spaced conductive bands comprise a heating member of a heating assembly.

[0015] Exemplary Embodiment 8: An aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein the aerosol source member further comprises a second substrate material defining an outer surface and an internal region, the second substrate material substantially surrounding the first substrate material.

[0016] Exemplary Embodiment 9: An aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein the outer surface of the first substrate material includes a plurality of spaced conductive bands.

[0017] Exemplary Embodiment 10: An aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein each of the separated conductive bands surrounds the entire outer surface of the substrate material.

[0018] Exemplary Embodiment 11: An aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein each of the separated conductive bands extends around a portion of the outer surface of the substrate material and defines a first end and a second end.

[0019] Exemplary Embodiment 12: Aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein, at the heating position, each spike of a plurality of spikes is in contact with the first and second ends of a separated conductive band.

[0020] Exemplary Embodiment 13: Aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein a plurality of spikes comprise a heating member of a heating assembly.

[0021] Exemplary Embodiment 14: Aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein a plurality of spaced conductive bands comprise a heating member of a heating assembly.

[0022] Exemplary Embodiment 15: An aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein the base material contains at least one of tobacco material and tobacco-derived material.

[0023] Exemplary Embodiment 16: An aerosol delivery device of any of the above-mentioned exemplary embodiments, or any combination of any of the above-mentioned exemplary embodiments, wherein the base material contains a non-tobacco material.

[0024] Exemplary Embodiment 17: An aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein the first base material contains the first composition, the second base material contains the second composition, and the first composition is different from the second composition.

[0025] Exemplary Embodiment 18: An aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein the base material comprises at least one of the following: fine fragments of tobacco material, beads of tobacco material, extruded structures of tobacco material, crimped sheets of tobacco material, and combinations thereof.

[0026] Exemplary Embodiment 19: An aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein the first base material comprises at least one of the following: fine fragments of tobacco material, beads of tobacco material, extruded structures of tobacco material, crimped sheets of tobacco material, and combinations thereof.

[0027] Exemplary Embodiment 20: An aerosol delivery device of any of the above-described exemplary embodiments, or any combination of any of the above-described exemplary embodiments, wherein the second base material comprises at least one of the following: fine fragments of tobacco material, beads of tobacco material, extruded structures of tobacco material, crimped sheets of tobacco material, and combinations thereof.

[0028] These and other features, aspects and advantages of this disclosure will become apparent upon reading the following detailed description, along with the accompanying drawings which are briefly described below.

[0029] The aspects of this disclosure are described using the general terminology described above, and will be referred to in the attached drawings, which are not necessarily drawn to scale. [Brief explanation of the drawing]

[0030] [Figure 1] A schematic front view of an aerosol delivery device, including a control body, an aerosol source member, and a heating assembly, according to an exemplary embodiment of the present disclosure, is shown. [Figure 2] The diagram shows a schematic front view of a portion of the heated end of the aerosol source member and a portion of the heating assembly according to an exemplary embodiment of the present disclosure. [Figure 3] The diagram shows a schematic perspective view of a portion of the heated end of the aerosol source member and a portion of the heating assembly according to an exemplary embodiment of the present disclosure. [Figure 4] This diagram shows a schematic perspective view of a portion of the heated end of an aerosol source member according to an exemplary embodiment of the present disclosure. [Figure 5] The diagram shows a schematic perspective view of a portion of the heated end of the aerosol source member and a portion of the heating assembly according to an exemplary embodiment of the present disclosure. [Figure 6] The diagram shows a schematic top view of the heated end of the aerosol source member and a portion of the heating assembly according to an exemplary embodiment of the present disclosure. [Figure 7] The diagram shows a schematic perspective view of a portion of the heated end of the aerosol source member and a portion of the heating assembly according to an exemplary embodiment of the present disclosure. [Figure 8] The diagram shows a schematic top view of the heated end of the aerosol source member and a portion of the heating assembly according to an exemplary embodiment of the present disclosure. [Modes for carrying out the invention]

[0031] This disclosure is described in further detail below with reference to its exemplary embodiments. These exemplary embodiments are described in such a manner that the disclosure is thorough and complete and fully conveys the scope of the disclosure to those skilled in the art. In fact, this disclosure may be embodied in many different forms and should not be construed as being limited to the embodiments described herein. Rather, these embodiments are provided so that the disclosure may satisfy applicable legal requirements. The singular nouns "a," "an," "the," etc., used herein and in the appended claims include multiple subjects unless otherwise explicitly indicated in the context. Also, while this specification may refer to quantitative measures, values, geometric relationships, etc., unless otherwise stated, one or more of these may be absolute or approximate to describe possible acceptable modifications, such as those due to technical tolerances.

[0032] As described below, exemplary embodiments of the present disclosure relate to aerosol delivery devices for use with aerosol source members. The aerosol delivery devices according to the present disclosure use electrical energy to heat a material (preferably without significantly burning the material) to form an inhalable substance. Components of such systems have the form of articles small enough to be considered handheld devices. That is, no smoke is produced when using preferred aerosol delivery device components, in the sense that the aerosol is mainly produced from the byproducts of the combustion or thermal decomposition of tobacco; rather, when using these preferred systems, vapor is produced due to the volatilization or vaporization of certain components incorporated therein. In some exemplary embodiments, components of the aerosol delivery device may be characterized as e-cigarettes, which most preferably incorporate tobacco and / or tobacco-derived components and thus deliver tobacco-derived components in aerosol form.

[0033] The aerosol-generating components of certain preferred aerosol delivery devices may produce a number of sensations of smoking a cigarette, cigar, or pipe (e.g., the form of inhalation and exhalation, the type of taste or flavor, the sensory stimulation effect, the physical feel, the form of use, the visual stimulation such as that produced by a visible aerosol) without any of their components substantially burning. For example, a user of an aerosol delivery device according to some exemplary embodiments of the present disclosure may hold and use its components in the same way a smoker uses a conventional smoking product, inhale one end of the component to inhale the aerosol produced by the component, inhale at selected time intervals, and so on.

[0034] While the system is generally described herein in relation to embodiments relating to aerosol delivery devices such as so-called “electronic cigarettes” or “heated tobacco products,” it should be understood that the mechanisms, components, features, and methods may be embodied in many different forms and associated with various articles. For example, the descriptions provided herein may be used in combination with embodiments of relevant packaging for any of the conventional smoking products (e.g., cigarettes, cigars, pipes, etc.), heated tobacco products, and the products disclosed herein. Therefore, it should be understood that the descriptions of mechanisms, components, features, and methods disclosed herein are discussed merely as examples relating to embodiments of aerosol delivery devices and can be embodied and used in various other products and methods.

[0035] The aerosol delivery devices of this disclosure can also be characterized as vapor products or pharmaceutical delivery articles. Such articles or devices may be adapted to deliver one or more substances (e.g., flavors and / or pharmaceutically active ingredients) in an inhalable form or state. For example, the inhalable substance may be substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance may be in aerosol form (i.e., a suspension of fine solid particles or droplets in a gas). For simplicity, the term “aerosol” as used herein means including vapors, gases and aerosols in forms or types suitable for human inhalation, regardless of whether they are visible or in a form that can be considered fuzzy. The physical form of the inhalable substance may depend on the nature of the device of the present invention and on the nature of the medium and on the inhalable substance itself in terms of whether it exists in a vapor or aerosol state. In some embodiments, terms may be interchangeable. Therefore, for simplicity, terms used to describe aspects of this disclosure are understood to be interchangeable unless otherwise specified.

[0036] The aerosol delivery devices of this disclosure generally include a number of components housed within an outer body or shell, which may be called a housing. The overall design of the outer body or shell is modifiable, and the form or configuration of the outer body, which can define the overall size and shape of the aerosol delivery device, is modifiable. Typically, an elongated body resembling the shape of a cigarette or cigar, or a fob-shaped body, may be formed from a single, integrated housing, or the housing may be formed from two or more separable bodies. For example, the aerosol delivery device may have an elongated shell or body whose shape is substantially tubular and which may resemble the shape of a conventional cigarette or cigar. In another example, the aerosol delivery device may have a box or fob shape. In one example, all components of the aerosol delivery device are housed within a single housing. Alternatively, the aerosol delivery device may have two or more joined and separable housings. For example, an aerosol delivery device may have a control body comprising a housing that contains one or more reusable components (e.g., a storage battery such as a rechargeable battery and / or a rechargeable supercapacitor, and various electronic devices for controlling the operation of the item), and a disposable part that can be detachably coupled thereto (e.g., a disposable flavor-containing aerosol source component). More specific forms, configurations, and arrangements of components within a single-housing type unit or a multi-component separable housing type unit will become apparent in light of further disclosures provided herein. Furthermore, various aerosol delivery device designs and component arrangements may be understood by considering commercially available electronic aerosol delivery devices.

[0037] As will be described in more detail below, the aerosol delivery apparatus of the present disclosure may comprise several combinations of an aerosol source member, including a power source (i.e., an electrical energy source), at least one control component (means for operating, controlling, regulating and stopping power for heating, such as by controlling the flow of current from the electrical energy source to other components of the apparatus (e.g., a microprocessor, individually or as part of a microcontroller)), a heater or heating element (e.g., an electrical resistance heating element or other component and / or an induction coil or other related component and / or one or more radiant heating elements), and a substrate material capable of generating an aerosol when sufficiently heated. In various embodiments, the aerosol source member may include a suction end or tip configured to allow the aerosol delivery apparatus to be drawn for aerosol inhalation (e.g., a defined airflow path through the apparatus so that the generated aerosol can be drawn out thereup upon inhalation).

[0038] The arrangement of components within the aerosol delivery device of this disclosure may vary across various embodiments. In some embodiments, the base material of the aerosol source member may be positioned close to the heating member to maximize aerosol delivery to the user. However, other configurations are not excluded. Generally, the heating member may be positioned close enough to the base material so that heat from the heating member can volatilize the base material (and, in some embodiments, one or more flavorings, drugs, etc., which may also be provided for delivery to the user) to form an aerosol for delivery to the user. When the heating member heats the base material, the aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the terms used herein mean that references to release, releasing, releases, or released are paraphrasable to include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, inhalable substances are released in the form of vapors, aerosols, or mixtures thereof, and such terms are used interchangeably herein unless otherwise specified.

[0039] As described above, various embodiments of aerosol delivery devices may incorporate batteries and / or other power sources to provide a sufficient current flow to the aerosol delivery device to perform various functions, such as powering a heating element, a control system, or an indicator. The electrical energy source may take various embodiments, as will be described in more detail below. Preferably, the electrical energy source may be capable of supplying enough power to rapidly operate a heating element to form an aerosol and to power the aerosol delivery device throughout use for a desired duration. Preferably, the electrical energy source is sized to fit conveniently within the aerosol delivery device so that the aerosol delivery device can be easily handled.

[0040] In further embodiments, the electrical energy source may also include a capacitor. A capacitor can discharge faster than a battery and can be charged between smoking sessions, thus allowing the capacitor to discharge at a lower rate than when a battery is 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. Therefore, the device may also include a charger component that can be attached to the smoking device between uses to replenish the supercapacitor.

[0041] Additional components are available for the aerosol delivery device of this disclosure. For example, the aerosol delivery device may include a flow sensor (e.g., a fume-sucking activated switch) that is sensitive to either pressure changes or airflow changes when a consumer inhales the device. Other possible current-actuated / deactivation mechanisms may include a temperature-actuated on / off switch or a lip pressure-actuated switch. An exemplary mechanism capable of providing such fume-sucking activating capability includes the Model 163PC01D36 silicon sensor manufactured by the MicroSwitch Division of Honeywell, Inc. in Freeport, Illinois. Typical flow sensors, current regulating components, and other current control components including various microcontrollers, sensors, and switches for aerosol delivery devices are all described in U.S. Patent No. 4,735,217 by Gerth et al., U.S. Patents No. 4,922,901, 4,947,874, and 4,947,875 by Brooks et al., U.S. Patent No. 5,372,148 by McCafferty et al., U.S. Patent No. 6,040,560 by Fleischhauer et al., U.S. Patent No. 7,040,314 by Nguyen et al., and U.S. Patent No. 8,205,622 by Pan, all of which are incorporated herein by reference in their entirety. Also referred to are the control schemes described in U.S. Patent No. 9,423,152 by Ampolini et al., which are also incorporated herein by reference in their entirety.

[0042] In another example, a personal vaporizer unit may comprise a first conductive surface configured to contact a first body part of a user holding the personal vaporizer unit, and a second conductive surface electrically isolated from the first conductive surface, configured to contact a second body part of the user. Thus, when the personal vaporizer unit detects a change in conductivity between the first and second conductive surfaces, the vaporizer is activated to vaporize a substance, which can then be inhaled by the user holding the unit. The first and second body parts may be lips or parts of the hands. The two conductive surfaces may also be used to charge a battery housed in the personal vaporizer unit. The two conductive surfaces may also form or be part of a connector that can be used to output data stored in memory. See U.S. Patent No. 9,861,773 by Terry et al., which is incorporated herein by reference in its entirety.

[0043] Furthermore, U.S. Patent No. 5,154,192 by Sprinkel et al. discloses an indicator for smoking products, U.S. Patent No. 5,261,424 by Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouthpiece end of a device to detect the movement of the user's lips associated with inhalation and subsequently cause heating of the heating device, and U.S. Patent No. 5,372,148 by McCafferty et al. discloses a smoke inhalation sensor for controlling the energy flow to a heating load array in response to a pressure drop through the mouthpiece, Ha U.S. Patent No. 5,967,148 by Rris et al. discloses a container in a smoking device that includes an identifier for detecting heterogeneity of the infrared transmittance of an inserted component and a controller that executes a detection routine when the component is inserted into the container; U.S. Patent No. 6,040,560 by Fleischhauer et al. describes a defined, viable power cycle having multiple differential phases; and U.S. Patent No. 5,934,289 by Watkins et al. describes a photonic-optronic component. The U.S. Patent No. 5,954,979 by Counts et al. discloses means for changing the draw resistance through a smoking device; the U.S. Patent No. 6,803,545 by Blake et al. discloses a specific battery configuration for use in a smoking device; the U.S. Patent No. 7,293,565 by Griffen et al. discloses various charging systems for use with a smoking device; the U.S. Patent No. 8,402,976 by Fernando et al. discloses computer interface means for a smoking device to facilitate charging and enable computer control of the device; the U.S. Patent No. 8,689,804 by Fernando et al. discloses an identification system for a smoking device; and PCT International Publication 2010 / 003480 by Flick discloses a fluid flow sensing system indicating smoke inhalation using an aerosol generation system. All of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0044] Examples of components related to electronic aerosol delivery articles and additional disclosed materials or components usable in the apparatus include U.S. Patent No. 4,735,217 by Gerth et al., U.S. Patent No. 5,249,586 by Morgan et al., U.S. Patent No. 5,666,977 by Higgins et al., U.S. Patent No. 6,053,176 by Adams et al., U.S. Patent No. 6,164,287 by White, U.S. Patent No. 6,196,218 by Voges, U.S. Patent No. 6,810,883 by Felter et al., U.S. Patent No. 6,854,461 by Nichols, U.S. Patent No. 7,832,410 by Hon, U.S. Patent No. 7,513,253 by Kobayashi, U.S. Patent No. 7,896,006 by Hamano, U.S. Patent No. 6,772,756 by Shayan, U.S. Patent No. 8, U.S. Patent No. 156,944 and U.S. Patent No. 8,375,957, U.S. Patent No. 8,794,231 by Thorens et al., U.S. Patent No. 8,851,083 by Oglesby et al., U.S. Patent No. 8,915,254 and U.S. Patent No. 8,925,555 by Monsees et al., U.S. Patent No. 9,220,302 by DePiano et al., and Hon's U.S. Patent Application Publication No. 2006 / 01965 References include U.S. Patent Publication No. 18 and U.S. Patent Application Publication No. 2009 / 0188490, U.S. Patent Application Publication No. 2010 / 0024834 by Oglesby et al., U.S. Patent Application Publication No. 2010 / 0307518 by Wang, PCT International Publication No. 2010 / 091593 by Hon, and PCT International Publication No. 2013 / 089551 by Foo, each of which is incorporated herein by reference in its entirety. Furthermore, U.S. Patent Application Publication No. 2017 / 0099877 by Worm et al., filed on 13 October 2015, discloses an aerosol delivery device and a capsule that may be included in a fob-shaped configuration for an aerosol delivery device, which is incorporated herein by reference in its entirety. In various embodiments, various materials disclosed in the aforementioned documents may be incorporated into the device, and each of the aforementioned disclosures is incorporated herein by reference in its entirety.

[0045] More specific forms, configurations, and arrangements of various substrate materials, aerosol source members, and components within the aerosol delivery apparatus of this disclosure will become apparent in light of the further disclosures provided below. In addition, the selection of various aerosol delivery apparatus components may be understood by considering commercially available electronic aerosol delivery apparatuses. Furthermore, the arrangement of components within an aerosol delivery apparatus may be understood by considering commercially available electronic aerosol delivery apparatuses.

[0046] Figure 1 shows a schematic front view of an exemplary embodiment of the aerosol delivery device 100 according to the present disclosure. Generally, the aerosol delivery device 100 of the illustrated embodiment includes a control body 102 which includes a housing 104 configured to receive an aerosol source member 200. In the illustrated embodiment, the control body 102 may include a control component 106 (e.g., a microprocessor, individually or as part of a microcontroller, a printed circuit board (PCB) including a microprocessor and / or a microcontroller) and an electrical energy source 108 (e.g., a battery which may be rechargeable, and / or a rechargeable supercapacitor). In various embodiments, one or both of the control component 106 and the electrical energy source 108 may be coupled to the housing 104. For the purposes of this application, the phrase “coupled” when used in relation to one component in comparison to another component may include embodiments in which one component is located 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 106 and the electrical energy source 108 are located within the housing. However, in other embodiments, one or both of the control component 106 and the electrical energy source 108 may be separate components. Additional information relating to the control component 106 and the electrical energy source 108 is provided below. In some embodiments, the housing 104 may also include a push button configured to activate a specific operation of the device 100, such as turning on the device and starting the heating of the heating element. In various embodiments, the aerosol source member 200 may comprise a heated end 202 configured to be inserted into the control body 102 and a suction end 204 into which the user draws to generate an aerosol.The aerosol delivery device in Figure 1 is shown having a substantially rectangular or fob-shaped control body 102 for ease of illustration, but in other embodiments the control body 102 may have any other shape, including an elongated shell or body that is substantially tubular and can therefore resemble the shape of a conventional cigarette or cigar, and it should be noted that the components described below may be sized and configured to fit inside an elongated body.

[0047] In certain embodiments, one or both of the control body 102 and the aerosol source member 200 may be described as disposable or reusable. For example, the control body 102 may have a replaceable or rechargeable battery, a solid-state battery, a thin-film solid-state battery, a rechargeable supercapacitor, etc., and may therefore be combined with any kind of charging technology, including connection to a wall charger, connection to a car charger (i.e., a cigarette lighter socket), 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), connection to a photocell (sometimes called a solar cell), or connection of a solar cell to a solar panel, wireless chargers such as chargers using inductive wireless charging (e.g., wireless charging compliant with the Qi wireless charging standard by the Wireless Power Consortium (WPC)), or radio frequency (RF) based chargers. An example of an inductive wireless charging system is described in its entirety by reference in U.S. Patent Application Publication No. 2017 / 0112196 by Sur et al. Disposable components for use with the control unit are disclosed in Chang et al.'s U.S. Patent No. 8,910,639, which is incorporated herein by reference in its entirety.

[0048] As described above, the control body 102 may further include a control component 106. For example, the control component 106 may include a control circuit (connectable to additional components, as further described herein) that can be connected to an electrical energy source 108 by conductive wires. In various embodiments, the control component 106 can control when and how the heating element receives electrical energy to heat an inhalable material medium for the release of an inhalable substance for inhalation by the consumer. Such control may relate to the operation of a pressure-sensitive switch, etc., which will be described in more detail below. It should be noted that the terms “connected” or “coupled” should not be interpreted as requiring a direct connection without the use of intermediary components. Rather, these terms may encompass direct connections and / or connections via one or more intermediary components. Thus, in various embodiments, these terms will be understood to mean operably connected or operably coupled.

[0049] In various embodiments, the control component 106 may also be configured to precisely control the amount of heat supplied to the base material. The heat required to volatilize the aerosol-forming material in sufficient volume to provide a desired dose of inhalable material in a single inhalation may vary for each specific material used, but 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 a suitable amount of aerosol-forming material and thereby provide a desired dose of inhalable material. However, it may be particularly desirable to avoid heating to a temperature substantially above about 550°C in order to avoid degradation and / or excessive premature volatilization of the aerosol-forming material. In particular, heating should be at a sufficiently low temperature and for a sufficiently short time so as to avoid significant combustion (preferably any combustion) of the inhalable material medium. The present disclosure can provide components of the Article in combinations and modes of use that produce a desired amount of inhalable material at relatively low temperatures. Therefore, yield may refer to either or both the generation of aerosols within the article and / or their delivery from the article to the consumer. In certain embodiments, the heating temperature may be about 120°C to about 300°C, about 130°C to about 290°C, about 140°C to about 280°C, about 150°C to about 250°C, or about 160°C to about 200°C. The duration of heating can be controlled by several factors, as will be described in more detail below. As will be described further herein, the heating temperature and duration may depend on the desired volume of aerosol and ambient air to be drawn through the aerosol source member. However, since the article may be configured such that the heating member is energized only until the desired temperature is reached, the duration may vary depending on the heating rate of the heating member. Alternatively, the duration of heating may be tied to the duration of smoke inhalation by the consumer using the article. In general, the heating temperature and time are controlled by one or more components housed in the control body, as described above.

[0050] The amount of inhalable material released by the aerosol source member can vary based on the properties of the inhalable material. Preferably, the aerosol source member is composed of a sufficient amount of inhalable material, along with a sufficient amount of any aerosol-forming agent, so as to function at a sufficient temperature for a sufficient time to release the desired amount over the course of use. The amount may be provided in a single inhalation from the aerosol source member, or it may be divided to be provided through several inhalations 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 amounts of nicotine of about 0.05 mg to about 1.0 mg, about 0.08 mg to about 0.5 mg, about 0.1 mg to about 0.3 mg, or about 0.15 mg to about 0.25 mg per inhalation using the aerosol source member. In other embodiments, the desired amount may be characterized in relation to the amount of wet total particulate matter delivered based on the duration and volume of inhalation. For example, when the aerosol source component is smoked under standard FTC smoking conditions of 2 seconds and 35 ml of smoke inhalation, it may deliver at least 1.0 mg of moist total particulate matter per smoke inhalation for a specified number of smoke inhalations (as described separately herein). Such tests 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 smoke inhalation may be at least 1.5 mg, at least 1.7 mg, at least 2.0 mg, at least 2.5 mg, at least 3.0 mg, about 1.0 mg to about 5.0 mg, about 1.5 mg to about 4.0 mg, about 2.0 mg to about 4.0 mg, or about 2.0 mg to about 3.0 mg.

[0051] As described above, in some embodiments, the aerosol delivery device 100 may include a push button that can be connected to a control component for manual control of the heating assembly 110. For example, in some embodiments, the consumer may energize the heating assembly 110 using the push button. Similar functions associated with the push button may be achieved by other mechanical or non-mechanical means (e.g., magnetic or electromagnetic). Thus, the operation of the heating assembly 110 is controllable by a single push button. Alternatively, multiple push buttons may be provided to control various operations separately. One or more push buttons present may be located substantially flush with the casing of the control body 102.

[0052] 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 the consumer's inhalation of an article (i.e., fume-activated heating). For example, the device may include a switch or flow sensor (not shown) (i.e., fume-activated switch) within the control body 102 that is sensitive to either a change in pressure or a change in airflow when the consumer inhales the article. Other suitable current-actuated / deactivation mechanisms may include a temperature-actuated on / off switch or a lip-pressure-actuated switch. An exemplary mechanism that can provide such fume-activated capability includes the Model 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc. in Freeport, Illinois. Using such a sensor, the heating element can be quickly activated by a change in pressure when the consumer inhales the device. Furthermore, to energize the heating assembly sufficiently quickly after sensing a change in airflow, a flow sensing device, such as one using the principle of hot-wire anemometry, may be used. An additional fume-absorbing switch that can be used is a pressure difference switch, such as model number MPL-502-V, range A, manufactured by Micro Pneumatic Logic, Inc. of Fort Lauderdale, Florida. Another preferred fume-absorbing mechanism is a pressure transducer (e.g., comprising an amplifier or gain stage) coupled to a comparator for detecting a given threshold pressure. Yet another preferred fume-absorbing mechanism is a vane deflected by airflow, the movement of which is detected by motion sensing means. Yet another preferred actuation mechanism is a piezoelectric switch. Also useful is the preferably 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 electric switches that can be used in heating circuits according to this disclosure are described in U.S. Patent No. 4,735,217 by Gerth et al., which is incorporated herein by reference in its entirety.Other suitable differential switches, analog pressure sensors, flow sensors, etc., will be apparent to those skilled in the art who are familiar with the present disclosure. In some embodiments, the control body 102 may include a pressure sensing tube or other passage providing a fluid connection between the fume-absorbing actuated switch and the aerosol source member 200, so that pressure changes during suction can be easily identified by the switch. Other exemplary fume-absorbing actuated devices that may be useful in accordance with the present disclosure are all disclosed in U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,874 by Brooks et al., U.S. Patent No. 5,372,148 by McCafferty et al., U.S. Patent No. 6,040,560 by Fleischhauer et al., and U.S. Patent No. 7,040,314 by Nguyen et al., all of which are incorporated herein by reference in their entirety.

[0053] When a consumer inhales the suction port end of the device 100, the current-actuated means can rapidly generate heat by ensuring that the flow of current through the heating assembly is not restricted or interrupted. For rapid heating, it may be useful to include a current-regulating component to (i) regulate the flow of current through the heating member to control the heating of the resistive element and the resulting temperature, and (ii) prevent overheating and degradation of the base material 210. In some embodiments, the current-regulating circuit may be time-based. Specifically, such a circuit may include means to ensure that the flow of current through the heating member is not interrupted for the initial period of inhalation, and subsequently timer means to regulate the flow of current until inhalation is complete. For example, the subsequent regulation may include rapid on-off switching of the flow of current (e.g., on the order of about 1 to 50 milliseconds) to maintain the heating member within a desired temperature range. Furthermore, the regulation may comprise simply ensuring that the flow of current is not interrupted until a desired temperature is achieved, and then completely turning off the flow of current. The heating element may be reactivated by the consumer initiating another fumigation of the article (or by manually activating a push button depending on the specific switch embodiment used to activate the heater). Alternatively, subsequent adjustment may involve modulating the flow of current through the heating element to maintain it within a desired temperature range. In some embodiments, the heating element may be energized for durations 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 release a desired dose of inhalable substance. One exemplary time-based current regulation circuit may include a transistor, timer, comparator, and capacitor. Suitable transistors, timers, comparators, and capacitors are commercially available and will be apparent to those skilled in the art. Exemplary timers include those available from NEC Electronics as the C-1555C and from General Electric Intersil, Inc. as the ICM7555, as well as so-called "555 timers" in various other sizes and configurations.An exemplary comparator is available from National Semiconductor as the LM311. Further descriptions of such time-referenced current regulation circuits are provided in Brooks et al., U.S. Patent No. 4,947,874, which is incorporated herein by reference in its entirety.

[0054] In light of the above, it can be understood that various mechanisms can be used to facilitate the activation / deactivation of the current to the heating element. For example, the device may include a timer for regulating the flow of current in an item (such as during consumer suction). The device may further include a timer-responsive switch for enabling and deactivating the flow of current to the heating element. The regulation of the current flow may also involve the use of a capacitor and components for charging and discharging the capacitor at a specified rate (e.g., a rate close to the rate at which the heating element heats and cools). The current flow may be regulated so that the flow of current through the heating element is not interrupted, particularly over the initial period of suction, but the current flow may be turned off or cycled alternately on and off after the initial period until suction is complete. Such a cycle may be controlled by a timer capable of generating a preset switching cycle, as described above. In certain embodiments, the timer may generate a periodic digital waveform. The flow during the initial period may be further regulated by using a comparator that compares a first voltage at a first input with a threshold voltage at a threshold input and generates an output signal when the first voltage is equal to the threshold voltage, thereby enabling the timer. Such embodiments may further include components for generating a threshold voltage at a threshold input and components for generating a threshold voltage at a first input after the first period has elapsed.

[0055] As described above, the electrical energy source 108 used to supply power to the various electrical components of the apparatus 100 may take various embodiments. Preferably, the electrical energy source can supply enough energy to rapidly heat the heating assembly in the manner described above and still be conveniently compatible with the apparatus 100 while supplying power to the apparatus through use by multiple aerosol source members 200. 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, a preferred electrical energy source is light enough not to impair the desired smoking experience. Several examples of possible electrical energy sources are described in U.S. Patent No. 9,484,155 by Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191 by Sur et al., filed October 21, 2015, whose entire disclosures are incorporated herein by reference.

[0056] 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 the N50-AAA CADNICA nickel-cadmium battery manufactured by Sanyo Electric Company, Ltd. in Japan. In yet another embodiment, for example, multiple such batteries providing 1.2 volts each may be connected in series. Other electrical energy sources, such as rechargeable manganese dioxide lithium batteries, may also be used. Any of these batteries or combinations thereof can be used as an electrical energy source, but rechargeable batteries are preferred due to the cost and disposal considerations associated with disposable batteries. In embodiments in which rechargeable batteries are used, the aerosol delivery device 100 may further include charging contacts that interact with corresponding contacts in a conventional charging unit (not shown) that obtains power from a standard 120-volt AC wall outlet or other power source, e.g., an automotive 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 smoke extractions, thus allowing the capacitor to discharge at a lower rate than when batteries are used to directly power the heating element. For example, a supercapacitor, i.e., an electric double-layer capacitor (EDLC), may be used separately from or in combination with batteries. When used alone, the supercapacitor may be charged before each use of the device 100. Therefore, the 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 disclosure, thin-film batteries may be used.

[0057] As described above, in various embodiments, the aerosol delivery device 100 may be equipped with one or more indicators (not shown). In various embodiments, one or more indicators may be located at any position on the control body 102. In some embodiments, the indicators may be lights (e.g., light-emitting diodes) capable of indicating multiple modes of use of the device. For example, a series of lights may correspond to the number of fume extractions of a given aerosol source member. Specifically, the lights may be illuminated sequentially with each fume extraction so that the consumer is notified that the aerosol source member has been consumed when all the lights are illuminated. Alternatively, all the lights may be illuminated when the aerosol source member is inserted into the housing, and the lights may be extinguished with each fume extraction so that the consumer is notified that the aerosol source member has been consumed when all the lights are extinguished. In yet another embodiment, there may be only a single indicator whose illumination can indicate that current is flowing to the heating member and the device is actively heating. This may prevent the 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 relation to on / off type visual indicators, other operational indicators are also included. For example, a visual indicator may also include a change in the color or intensity of a light to indicate the progression of the smoking experience. Tactile and audible indicators are similarly included in this disclosure. Furthermore, combinations of such indicators may be used in a single device.

[0058] In various embodiments, the housing 104 may be formed from any material suitable for forming and maintaining a suitable structure, such as a tubular or rectangular shape, and suitable for holding an aerosol source member therein. In some embodiments, the housing may be formed from a single wall or multiple walls and from one or more heat-resistant materials (natural or synthetic) such that it maintains its structural integrity (e.g., does not degrade) at at least a certain temperature, which is the heating temperature provided by the electric heating member, as further described herein. In some embodiments, a heat-resistant polymer may be used. In other embodiments, a ceramic material may be used. In further embodiments, an insulating material may be used to prevent unnecessary heat transfer from the aerosol source member. If the housing is formed from a single layer, it 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 functions described above or that can be used as substitutes for the materials and components described above may be of the types described in Crooks et al. U.S. Patent Application Publication 2010 / 00186757 and Sebastian et al. U.S. Patent Application Publication 2011 / 0041861, the entire disclosures of these documents incorporated herein by reference.

[0059] Referring to Figures 1 and 2, the aerosol source member 200 defines an outer surface 206 and an inner region 208. In the illustrated embodiments, the base material 210 is located in the inner region 208 of the heated end 202 of the aerosol source member 200. However, in some embodiments, the base material may be located at both the heated end 202 and the mouthpiece end 204 of the aerosol source member 200. In the illustrated embodiments, the base material 210 has a single segment, but in other embodiments, the base material 210 may include additional segments that may have different compositions. For example, the heated end 202 of some embodiments of the aerosol source member 200 may further include a second base material segment (not shown). In various embodiments, one or more of the base materials may contain tobacco or tobacco-related materials together with an aerosol precursor composition bound thereto. In other embodiments, non-tobacco materials such as cellulose pulp materials may be used. In other embodiments, the non-tobacco base material may not be a plant-derived material. Other possible compositions, components, and / or additives for use with a single substrate material (and / or multiple substrate materials) are described in further detail below. It should be noted that the subsequent descriptions should be applicable to any substrate material or substrate material segment usable in the aerosol delivery devices described herein.

[0060] In various embodiments, the aerosol source member 200 or a portion thereof may be encased in an outer packaging material. In various embodiments, the mouthpiece end 204 of the aerosol source member 200 may include a filter, which may be manufactured from, for example, cellulose acetate material or polypropylene material. The filter may additionally or alternatively include strands of tobacco-containing material, such as those described in U.S. Patent No. 5,025,814 of Raker et al., which is incorporated herein in whole by reference. In various embodiments, the filter may enhance the structural integrity of the mouthpiece end of the aerosol source member and / or optionally provide filtration capacity and / or provide resistance to inhalation. The outer packaging material may comprise a material that resists heat transfer, which may include paper or other fibrous materials such as cellulose material. The outer packaging material may also include at least one filler material embedded or dispersed within the fibrous material. In various embodiments, the filler material may be in the form of water-insoluble particles. Furthermore, the filler material may incorporate inorganic components. In various embodiments, the outer packaging may be formed from multiple layers, such as an underlying bulk layer, and a top layer, such as the wrapping paper typical in cigarettes. Such materials may include, for example, lightweight “rag fibers” such as flax, hemp, sisal, rice straw, and / or esparto. The outer packaging may also contain materials typically used in the filter elements of conventional cigarettes, such as cellulose acetate. Furthermore, the excess length of the outer packaging at the mouthpiece end 204 of the aerosol source member may function to simply separate the base material from the consumer’s mouth, or to provide space for arranging filter material, or to affect the inhalation to the article, or to affect the flow characteristics of the vapor or aerosol exiting the device during inhalation, as described below. Additional descriptions of the composition of outer packaging materials usable with this disclosure can be found in Worm et al., U.S. Patent No. 9,078,473, which is incorporated herein by reference in its entirety.

[0061] In general, the shape and dimensions of the aerosol source members in the various embodiments described herein depend on the size of the housing, the physical properties of heat and mass transfer related to the shape design, and / or the expected number of flue gases absorbed by the aerosol source member. A variety of different shapes (e.g., cylindrical, cubic, spherical, etc.) and dimensions are possible, but in some embodiments, an aerosol source member having a cylindrical shape may have an overall diameter of about 5.4 mm and a length of about 83 mm. In other embodiments, the aerosol source member may have an overall diameter of about 7-8 mm (e.g., about 7.8 mm, etc.) or more. In other embodiments, an aerosol source member having a cubic shape may have dimensions of about 70 mm × 20 mm × 6 mm. In any of these examples, the dimensions may vary considerably, for example, by ±50% for any given dimension.

[0062] In various embodiments, heating of the base material 210 results in the aerosolization of the aerosol precursor composition bound to the base material 210. In various embodiments, the suction end 204 of the aerosol source member 200 is configured to receive the generated aerosol through it in response to suction applied to the suction end 204 by the user. As described above, the suction end 204 of the aerosol source member 200 in some embodiments may include a filter configured to receive the aerosol through it in response to suction applied to the suction end 204 of the aerosol source member. Preferably, the elements of the base material 210 do not undergo significant thermal decomposition (e.g., carbonization, charring, or combustion), and the aerosolized components are taken into the air, which is then drawn into the user's mouth through the aerosol delivery device 100, which includes a filter (if present).

[0063] In one embodiment, the base material may contain a blend of flavorful aromatic tobacco in cut-filler form. In another embodiment, the base material may contain reconstituted tobacco material as described in U.S. Patent No. 4,807,809, Pryor et al., U.S. Patent No. 4,889,143 and Raker, U.S. Patent No. 5,025,814, whose entire disclosure is incorporated herein by reference. Furthermore, the reconstituted tobacco material may include reconstituted tobacco paper for the type of cigarette described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, RJ Reynolds Tobacco Company Monograph (1988), whose entire content is incorporated herein by reference. For example, the reconstituted tobacco material may include a sheet-like material containing tobacco and / or tobacco-related material. Thus, in some embodiments, the base material may be formed from a wound roll of reconstituted tobacco material. In another embodiment, the base material may be formed from fine fragments, shards, etc., 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 overlapping layers (e.g., a gathered web) which may or may not include thermally conductive components. An example of a substrate material comprising a series of overlapping layers (e.g., a gathered web) of an initial substrate sheet formed of 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 on 26 February 2018, titled "Heat Conducting Substrate For Electrically Heated Aerosol Delivery Device," which is incorporated herein by reference in its entirety.

[0064] In some embodiments, the base material may contain a plurality of microcapsules, beads, granules, etc., having tobacco-related materials. For example, a typical microcapsule may be substantially spherical in shape and may have an outer cover or shell containing a liquid central region such as a tobacco-derived extract. In some embodiments, one or more of the base materials may contain a plurality of microcapsules, each formed in a hollow cylindrical shape. In some embodiments, one or more of the base 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.

[0065] The tobacco used in one or more of the base materials may include, or be derived from, yellow tobacco, Burley tobacco, Oriental tobacco, Maryland tobacco, dark tobacco, dark tumbled tobacco and Rustika tobacco, as well as other rare or specialty tobaccos, or blends thereof. Various representative tobacco types, tobacco processing types, and tobacco blend types are incorporated herein by reference in their entirety by reference in U.S. Patent No. 4,836,224 by Lawson et al., U.S. Patent No. 4,924,888 by Perfetti et al., U.S. Patent No. 5,056,537 by Brown et al., U.S. Patent No. 5,159,942 by Brinkley et al., U.S. Patent No. 5,220,930 by Gentry, U.S. Patent No. 5,360,023 by Blakley et al., and Shafer. This is described in U.S. Patent No. 6,701,936 by Li et al., U.S. Patent No. 6,730,832 by Dominguez et al., U.S. Patent No. 7,011,096 by Li et al., U.S. Patent No. 7,017,585 by Li et al., U.S. Patent No. 7,025,066 by Lawson et al., U.S. Patent Application Publication No. 2004 / 0255965 by Perfetti et al., PCT International Publication No. 02 / 37990 by Bereman and Fund.Appl.Toxicol.,39,p.11-17(1997).

[0066] In yet another embodiment of this disclosure, the base material may contain tobacco, tobacco-related materials, glycerin, water and / or binder materials, or an extruded structure essentially composed of them, although certain formulations do not need to contain binder materials. In various embodiments, suitable binder materials may include alginates such as ammonium alginate, propylene glycol alginate, potassium alginate and sodium alginate. Alginates, particularly high-viscosity alginates, may be used in combination with controlled levels of free calcium ions. Other suitable binder materials include hydroxypropyl cellulose such as Klucel H from Aqualon Co.; hydroxypropyl methylcellulose such as Methocel K4MS from The Dow Chemical Co.; hydroxyethyl cellulose such as Natrosol 250 MRCS from Aqualon Co.; microcrystalline cellulose such as Avicel from FMC; methylcellulose such as Methocel A4M from The Dow Chemical Co.; and sodium carboxymethyl cellulose such as CMC 7HF and CMC 7H4F from Hercules Inc. Further possible binder materials include starch (e.g., corn starch), guar gum, carrageenan, locust bean gum, pectin, and xanthan gum. In some embodiments, a combination or blend of two or more binder materials may be used. Other examples of binder materials are described, for example, in U.S. Patent No. 5,101,839 by Jakob et al. and U.S. Patent No. 4,924,887 by Raker et al., which are incorporated herein in their entirety by reference, respectively. In some embodiments, the aerosol-forming material may be provided as part of the binder material (e.g., propylene glycol alginate). Furthermore, in some embodiments, the binder material may contain fine cellulose or nanocellulose derived from tobacco or other biomass.

[0067] In some embodiments, the base material may include an extruded material, as described in U.S. Patent Application Publication 2012 / 0042885 by Stone et al., which is incorporated entirely herein by reference. In yet another embodiment, the base material may include an extruded structure and / or base formed from marmelized and / or unmarmelized tobacco. Marmelized tobacco is known, for example, by U.S. Patent No. 5,105,831 by Banerjee et al., which is incorporated entirely herein by reference. Marmelized tobacco, together with the binders and / or flavorings described herein, contains about 20 to about 30 wt percent glycerol and calcium carbonate (generally about 10 to about 60 wt percent, often about 40 to about 60 wt percent) in powder form of a tobacco blend. In various embodiments, the extruded material may have one or more longitudinal openings.

[0068] In various embodiments, the base material may take on various structures based on the varying amounts of material used therein. For example, the sample base material may contain up to about 98% by weight, up to about 95% by weight, or up to about 90% by weight of tobacco and / or tobacco-related materials. The sample base material may also contain up to about 25% by weight, up to about 20% by weight, or up to about 15% by weight of water, particularly about 2% to about 25% by weight, up to about 5% to about 20% by weight, or up to about 7% to about 15% by weight of water. Flavorings, etc. (including drugs such as nicotine) may contain up to about 10% by weight, up to about 8% by weight, or up to about 5% by weight of aerosol delivery components.

[0069] Additionally or alternatively, the substrate material may comprise an extruded structure and / or substrate containing or essentially composed of tobacco, glycerin, water, and / or a binder material, further configured to substantially maintain its structure throughout the aerosol-generating process. That is, the substrate material may be configured to substantially maintain its shape throughout the aerosol-generating process (e.g., the substrate material does not deform continuously under applied shear stress). Such exemplary substrate materials may contain liquid and / or some water content, but the substrate may remain substantially solid throughout the aerosol-generating process and substantially maintain its structural integrity throughout the aerosol-generating process. Exemplary tobacco and / or tobacco-related materials suitable for substantially solid substrate materials are described in the U.S. Patent Application Publication No. 2015 / 0157052 by Ademe et al., U.S. Patent Application Publication No. 2015 / 0335070 by Sears et al., U.S. Patent No. 6,204,287 by White, and U.S. Patent No. 5,060,676 by Hearn et al., which are incorporated herein by reference in their entirety.

[0070] In some embodiments, the amount of base material used in the aerosol delivery device may be such that the article exhibits acceptable sensory and sensory stimulation characteristics, as well as desirable performance characteristics. For example, in some embodiments, an aerosol precursor composition, such as glycerin and / or propylene glycol, may be used in the base material to produce a visible mainstream aerosol that in many respects resembles the appearance of cigarette smoke.

[0071] Representative types of additional aerosol precursor compositions are described in U.S. Patent No. 4,793,365 by Sensabaugh, Jr. et al., U.S. Patent No. 5,101,839 by Jakob et al., PCT International Publication No. 98 / 57556 by Biggs et al., and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, RJ Reynolds Tobacco Company Monograph (1988), the disclosure of which is incorporated herein by reference. In some embodiments, the base material can produce a visible aerosol when sufficiently heated (and cooled by air as necessary), and the base material can produce a “smoky” aerosol. In other embodiments, the base material can produce an aerosol that is substantially invisible but is perceived as present by other properties such as flavor or texture. Thus, the properties of the aerosol produced may be variable depending on the specific components of the aerosol delivery components. The base material may be chemically simpler compared to the chemical properties of smoke produced by burning tobacco.

[0072] In another embodiment, the aerosol delivery device according to the present disclosure may include a base material comprising a porous inert material, such as a ceramic material. For example, in some embodiments, ceramics of various shapes and forms (e.g., beads, rods, tubes, etc.) having various pore morphologies may be used. Furthermore, in some embodiments, a non-tobacco material, such as e-liquid, may be filled into the ceramic. In another embodiment, the base material may contain a porous inert material that does not substantially react chemically and / or physically with tobacco-related materials, such as tobacco-derived extracts. Furthermore, extruded tobacco, such as those described above, may be porous. For example, in some embodiments, the extruded tobacco material may contain an inert gas, such as nitrogen, which functions as a foaming agent during the extrusion process.

[0073] As described above, in some embodiments, one or more of the base materials may contain tobacco, tobacco components and / or tobacco-derived materials that have been treated, manufactured, produced and / or processed to incorporate an aerosol precursor composition (e.g., a humectant, e.g., propylene glycol, glycerin, etc.) and / or at least one flavoring, as well as a flame retardant / flame retarder (e.g., diammonium phosphate and / or another salt) configured to help prevent ignition, thermal decomposition, combustion and / or charring of the base material by a heat source. Various forms and methods for incorporating tobacco into smoking products, in particular smoking products designed to intentionally prevent substantially any tobacco within the product from burning, are described in U.S. Patent No. 4,947,874 by Brooks et al., U.S. Patent No. 7,647,932 by Cantrell et al., U.S. Patent No. 8,079,371 by Robinson et al., U.S. Patent No. 7,290,549 by Banerjee et al., and U.S. Patent Application Publication No. 2007 / 0215167 by Crooks et al., whose entire disclosure is incorporated herein by reference.

[0074] As described above, in some embodiments, flame retardant / burn retardant materials and other additives may be included in one or more of the base materials and may include 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, ammonium ethanol borate, ammonium sulfamate, halogenated organic compounds, thiourea, and antimony oxide are also suitable but not preferred agents. In each embodiment of flame retardant, burn retardant, and / or char retardant materials used in base materials and / or other components (whether alone or in combination with each other and / or other materials), the desired properties are provided, most preferably without undesirable gas emission or molten behavior.

[0075] According to other embodiments of this disclosure, the base material may also incorporate tobacco additives of the types conventionally used in the manufacture of tobacco products. These additives may contain materials of the type used to enhance the flavor and aroma of tobacco used in the manufacture of cigars, cigarettes, pipes, etc. For example, these additives may contain various cigarette flavoring components and / or top-layer components. See, for example, U.S. Patent No. 3,419,015 by Wochnowski, U.S. Patent No. 4,054,145 by Berndt et al., U.S. Patent No. 4,887,619 by Burcham, Jr. et al., U.S. Patent No. 5,022,416 by Watson, U.S. Patent No. 5,103,842 by Strang et al., and U.S. Patent No. 5,711,320 by Martin, whose entire disclosure is incorporated herein by reference. Preferred flavoring materials may include water, sugars and syrups (e.g., sucrose, glucose and high-fructose corn syrup), humectants (e.g., glycerin or propylene glycol), and flavorings (e.g., cocoa and licorice). These additives may also contain top-layer materials (e.g., flavoring materials such as menthol). See, for example, U.S. Patent No. 4,449,541 by Mays et al., whose entire disclosure is incorporated herein by reference. Additional materials that may be added include those disclosed in U.S. Patent No. 4,830,028 by Lawson et al. and U.S. Patent No. 8,186,360 by Marshall et al., whose entire disclosure is incorporated herein by reference.

[0076] A wide variety of flavorings or materials that alter the sensory or sensory-stimulating properties or characteristics of the mainstream aerosol of a smoking product may be suitable for use. In some embodiments, such flavorings may be supplied from sources other than tobacco and may be natural or artificial in nature. For example, some flavorings may be applied to or incorporated into the base material and / or the area of ​​the smoking product where the aerosol is produced. In some embodiments, such flavorings may be supplied directly to a heating cavity or area adjacent to a heat source, or provided together with the base material. Exemplary flavorings may include, for example, vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, and flavorings and flavoring packages of types and characteristics conventionally used in flavorings for cigarettes, cigars, and pipe tobacco. Syrups such as high-fructose corn syrup may also be suitable for use.

[0077] The flavorings may also contain acidic or basic properties (e.g., organic acids such as levulinic acid, succinic acid, pyruvic acid, and benzoic acid). In some embodiments, the flavorings may be combined with elements of the base material as desired. Exemplary plant-derived compositions that may be suitable are disclosed together in U.S. Patent No. 9,107,453 and U.S. Patent Application Publication No. 2012 / 0152265 by Dube et al., which are incorporated herein by reference in their entirety. Any of the materials that can be useful in combination with the tobacco material to affect its sensory properties, including sensory stimuli properties as described herein, may be combined with the base material. In particular, organic acids can be incorporated into the base material to affect the flavor, sensation, or sensory stimuli properties of drugs such as nicotine that can be combined with the base material. For example, organic acids such as levulinic acid, lactic acid, and pyruvic acid may be included in the base material together with nicotine in amounts up to equimolar (based on the total organic acid content). Any combination of organic acids may be preferred. For example, in some embodiments, the base material may contain about 0.1 to about 0.5 moles of levulinic acid, about 0.1 to about 0.5 moles of pyruvic acid, about 0.1 to about 0.5 moles of lactic acid, or a combination thereof, per mole of nicotine, up to a concentration where the total amount of organic acids present is equimolar to the total amount of nicotine present in the base material. Various additional examples of organic acids used to produce the base material are described in U.S. Patent Application Publication No. 2015 / 0344456 by Dull et al., which is incorporated in its entirety herein by reference.

[0078] The selection of such additional components may be variable based on factors such as the desired sensory characteristics of the smoking product, and this disclosure is intended to encompass any such additional components that are readily apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972), whose entire disclosure is incorporated herein by reference.

[0079] In other embodiments, the base material may include other materials having various unique features or properties. For example, the base material may include plasticizing materials in the form of rayon or regenerated cellulose. Another example that can be preferred is viscose (commercially available as VISIL(R)), which is a regenerated cellulose product incorporating silica. Some carbon fibers may contain at least 95 percent or more carbon. Similarly, natural cellulose fibers such as cotton can be preferred, and natural cellulose fibers such as cotton may be impregnated with silica, carbon or metal particles, or treated with silica, carbon or metal particles to enhance flame retardancy and, in particular, minimize the release of any undesirable gas-releasing components that would adversely affect the flavor (in particular, minimize the possibility of any harmful gas-releasing products). To provide the desired flame retardancy, cotton may be treated with, for example, boric acid or various organophosphate compounds by immersion, spraying, or other techniques known in the art. These fibers could also be treated with organic or metal nanoparticles to impart desired flame-retardant properties without undesirable gas release or melting behavior (e.g., coating by immersion, spraying, or vapor deposition, injection, or both).

[0080] In the illustrated embodiment, the cross-section of the aerosol source member 200 may be substantially circular so as to define a substantially cylindrical shape extending between its opposing first and second ends. However, in other embodiments, the aerosol source member 200 may have a substantially non-circular cross-section so as to define a substantially non-cylindrical shape between its opposing first and second ends. Otherwise, in other examples, the aerosol source member 200 may include a cross-section that is asymmetrical with respect to an axis.

[0081] Although not shown in the figure, the housing 104 may include one or more apertures to allow ambient air to enter and be directed to the heated end 202 of the aerosol source member 200. Thus, when a consumer inhales into the inhalation end 204 of the aerosol source member 200, air can enter the aerosol source member 200 adjacent to the heated end 202, be drawn through the inhalable substance medium, and be inhaled by the consumer through the inhalation end 204. In embodiments where an upper casing is present, as will be described in more detail below, the inhaled air can carry the inhalable substance through an optional filter and out of the opening of the upper casing.

[0082] In some embodiments, the control body 102 may also include a flow sensor (not shown, e.g., a fume extraction sensor or a pressure switch). In other embodiments, the control body 102 may alternately or further include an actuation button (not shown). With respect to flow sensors, typical current regulating components, as well as other current regulating components including various microcontrollers, sensors and switches for aerosol delivery devices, are all described in U.S. Patent No. 4,735,217 by Gerth et al., all of which are incorporated herein by reference in their entirety, U.S. Patents No. 4,922,901, 4,947,874 and 4,947,875 by Brooks et al., U.S. Patent No. 5,372,148 by McCafferty et al., U.S. Patent No. 6,040,560 by Fleischhauer et al., U.S. Patent No. 7,040,314 by Nguyen et al., and U.S. Patent No. 8,205,622 by Pan. See also the control scheme described in U.S. Patent No. 9,423,152 by Ampolini et al., which is incorporated in its entirety herein by reference.

[0083] Further components may be used in the aerosol delivery devices of this disclosure. For example, U.S. Patent No. 5,154,192 by Sprinkel et al. discloses an indicator for smoking products; U.S. Patent No. 5,261,424 by Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouthpiece end of a device to detect the movement of the user's lips associated with inhalation and subsequently cause heating of the heating device; U.S. Patent No. 5,372,148 by McCafferty et al. discloses a smoke inhalation sensor for controlling the energy flow to a heating load array in response to a pressure drop through a mouthpiece; U.S. Patent No. 5,967,148 by Harris et al. discloses a container in a smoking device including an identifier for detecting non-uniformity of the infrared transmittance of an inserted component and a controller that performs a detection routine when the component is inserted into the container; U.S. Patent No. 6,040,560 by Fleischhauer et al. describe a defined, viable power cycle having multiple differential phases; and U.S. Patent No. 5,934,28 by Watkins et al. U.S. Patent No. 9 discloses photonic optronic components; U.S. Patent No. 5,954,979 by Counts et al. discloses means for changing the pull resistance through a smoking device; U.S. Patent No. 6,803,545 by Blake et al. discloses specific battery configurations for use in a smoking device; U.S. Patent No. 7,293,565 by Griffen et al. disclose various charging systems for use with a smoking device; U.S. Patent No. 8,402,976 by 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 by Fernando et al. discloses identification systems for smoking devices; and PCT International Publication No. 2010 / 003480 by Flick discloses a fluid flow sensing system indicating smoke inhalation using an aerosol generation system. All of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0084] Examples of components and disclosed materials or additional components relating to electronic aerosol delivery devices that may be used in this Article include U.S. Patent No. 4,735,217 by Gerth et al., U.S. Patent No. 5,249,586 by Morgan et al., U.S. Patent No. 5,666,977 by Higgins et al., U.S. Patent No. 6,053,176 by Adams et al., U.S. Patent No. 6,164,287 by White, U.S. Patent No. 6,196,218 by Voges, U.S. Patent No. 6,810,883 by Felter et al., U.S. Patent No. 6,854,461 by Nichols, U.S. Patent No. 7,832,410 by Hon, U.S. Patent No. 7,513,253 by Kobayashi, U.S. Patent No. 7,896,006 by Hamano, U.S. Patent No. 6,772,756 by Shayan, and U.S. Patent No. U.S. Patent Nos. 8,156,944 and 8,375,957 by Japan Patent Office, U.S. Patent No. 8,794,231 by Thorens et al., U.S. Patent No. 8,851,083 by Oglesby et al., U.S. Patent Nos. 8,915,254 and 8,925,555 by Monsees et al., U.S. Patent No. 9,220,302 by DePiano et al., and U.S. Patent Application Publication No. 2006 / 019651 by Hon. References include U.S. Patent Application Publication No. 8 and U.S. Patent Application Publication No. 2009 / 0188490, U.S. Patent Application Publication No. 2010 / 0024834 by Oglesby et al., U.S. Patent Application Publication No. 2010 / 0307518 by Wang, PCT International Publication No. 2010 / 091593 by Hon, and PCT International Publication No. 2013 / 089551 by Foo, each of which is incorporated herein by reference in its entirety. Furthermore, U.S. Patent Application No. 14 / 881,392 by Worm et al., filed October 13, 2015, discloses an aerosol delivery device and a capsule that may be included in a fob-shaped configuration for an aerosol delivery device, which is incorporated herein by reference in its entirety. In various embodiments, various materials disclosed in the aforementioned documents may be incorporated into the device, and each of the aforementioned disclosures is incorporated herein by reference in its entirety.

[0085] In some embodiments, the aerosol delivery device may include input elements (which may replace or complement airflow sensors or pressure sensors). These input elements may be included to allow a user to control the device's functions and / or output information to the user. Any component or combination of components may be used as input elements for controlling the device's functions. For example, one or more push buttons may be used, as described in Worm et al., U.S. Patent Application Publication 2015 / 0245658, incorporated herein by reference. Similarly, a touchscreen may be used, as described in Sears et al., U.S. Patent Application 14 / 643,626, filed March 10, 2015, incorporated herein by reference. As a further example, a component adapted to gesture recognition based on specific movements of the aerosol delivery device may be used as an input. See Henry et al., U.S. Patent Application Publication 2016 / 0158782, incorporated herein by reference. As yet another example, a capacitive sensor may be implemented in an aerosol delivery device, allowing the user to provide input by touching the surface of the device on which the capacitive sensor is implemented.

[0086] As described above, the aerosol delivery device 100 of the illustrated embodiment also includes a heating assembly 110 that receives power from an electrical energy source 108 and, in some embodiments, can be controlled by a control component 106. In various embodiments, the heating assembly 110 may include a heating element that can be any device suitable for providing enough heat to facilitate the release of an inhalable substance for inhalation by a consumer. In certain embodiments, the electric heating element may be a resistance heating element. A useful heating element can have low mass, low density, and moderate resistivity and be thermally stable at the temperature experienced during use. A useful heating element heats and cools rapidly, thus using energy efficiently. Also, rapid heating of the element causes the aerosol-forming material to volatilize almost immediately. Rapid cooling prevents substantial volatilization (and thus waste) of the aerosol-forming material during periods when aerosol formation is not desired. Such a heating element also allows for relatively precise control of the temperature range experienced by the aerosol-forming material, especially when time-based current control is used. A useful heating element is also chemically non-reactive (and chemically non-catalytic) with the material containing the inhalable substance medium being heated, so as not to adversely affect the flavor or content of the resulting aerosol or vapor. Exemplary and non-limiting materials that can constitute a heating element include a variety of metallic and ceramic materials. Other specific non-limiting examples include carbon, graphite, carbon / graphite composites, metal carbides and non-metallic carbides, nitrides, silicides, intermetallic compounds, cermets, metal alloys, and metal foils. Refractory materials, in particular, would be useful. Various different materials can be mixed to achieve desired properties of resistivity, mass, thermal conductivity, and surface characteristics.

[0087] In some embodiments, the heating element may be provided in other forms, such as foil, foam, mesh, hollow sphere, hemisphere, disc, helix, fiber, wire, film, thread, strip, ribbon, or cylinder. Such heating elements often comprise a metallic material and are configured to generate heat as a result of electrical resistance associated with the passage of electric current. Such resistive heating elements may be positioned in close proximity to and / or in direct contact with the substrate portion. As will be described in more detail below, the heating assembly or heating element may be positioned in the control body and / or aerosol source member. In various embodiments, the substrate portion may include components (i.e., thermally conductive components) that are embedded in or otherwise part of the substrate portion so as to function as a heating assembly or to facilitate the function of a heating assembly. Several examples of various heating elements and heating components are described in Worm et al., U.S. Patent No. 9,078,473, the disclosure of which is incorporated herein by reference in its entirety.

[0088] Some non-limiting examples of various heating member configurations include configurations in which the heating member or heating element is positioned in close proximity to the aerosol source member. For example, in some examples, at least a portion of the heating member may surround at least a portion of the aerosol source member. In other examples, one or more heating members may be positioned adjacent to the outside of the aerosol source member when inserted into the control body. In other examples, when the aerosol source member is inserted into the control body, at least a portion of the heating member may penetrate at least a portion of the aerosol source member (e.g., one or more protrusions and / or spikes penetrating the aerosol source member).

[0089] A heating element may be formed using various embodiments of a material configured to generate heat when an electric current is applied. Examples of materials that may form a wire coil include Kanthal (FeCrAl), nichrome, nickel, stainless steel, indium tin oxide, tungsten, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al)2), titanium, platinum, silver, palladium, silver and palladium alloys, graphite and graphite-based materials (e.g., carbon-based foams and threads), conductive inks, boron-doped silica, and ceramics (e.g., positive temperature coefficient ceramics or negative temperature coefficient ceramics). The heating element may be a resistive heating element or a heating element configured to generate heat by induction. The heating element may be coated with a thermally conductive ceramic, such as aluminum nitride, silicon carbide, beryllium oxide, alumina, silicon nitride, or composites thereof.

[0090] As will be described in more detail below, in some of the illustrated embodiments, multiple spikes function as heating elements. In other illustrated embodiments, multiple spaced-out bands function as heating elements in addition to, or as a substitute for, multiple spikes.

[0091] As shown in Figure 1, the heating assembly 110 includes a plurality of spikes 112 configured to articulate between a retracted position in which the spikes are not in contact with the aerosol source member and a heating position in which the spikes are in contact with the aerosol source member 200. In particular, Figure 1 shows the spikes 112 in the heating position. In various embodiments of the heating position, the spikes not only contact the aerosol source member 200 but also penetrate the outer surface 206 of the aerosol source member 200 such that a portion of the spikes 112 extends into the base material 210. In various embodiments, the extent to which the spikes 112 extend into the base material may vary. For example, in some embodiments, the spikes 112 may extend only a short distance into the base material, while in other embodiments, the spikes 112 may extend to the center of the base material 210, and in yet another embodiment, the spikes 112 may penetrate the center of the base material 210.

[0092] In various embodiments, the multiple spikes 112 may comprise opposing rows of spikes 112, as shown in Figures 1 and 2, where one row is positioned on one side of the aerosol source member 200 and the other row is positioned on the opposite side of the aerosol source member 200. Note that in some embodiments, additional rows of spikes 112 may be present, such as three or more rows that can be positioned around the circumference of the heated end 202 of the aerosol source member 200. However, in other embodiments, a single row of spikes 112 may be present. In some embodiments, the positioning of individual spikes 112 may be staggered between rows, as shown in Figures 1 and 2, while in other embodiments, the positioning of individual spikes 112 may be substantially aligned. In various embodiments, the articulation of the multiple spikes 112 can occur in various ways. For example, in some embodiments, the multiple spikes 112 may be housed in a clamshell housing that moves away from the aerosol source member 200 in the retracted position and toward the aerosol source member 200 in the heated position. In some embodiments, the operation of the joint movement may be triggered by a button. For example, in some embodiments, the clamshell housing may be spring-loaded, and a button may be triggered to move the clamshell housing from the retracted position to the heated position. In another embodiment, the user may slide a feature portion that moves one or both of the rows of spikes 112 from the retracted position to the heated position, where the spikes 112 penetrate the outer surface 206 of the base material and enter a portion of its internal region 208. In the embodiments shown in the figures, the spikes are schematically shown as having a substantially conical shape, but it should be noted that in various other embodiments, the spikes may have a variety of other shapes, including, for example, a substantially cylindrical shape, a substantially prismatic shape, a substantially cubic shape, etc., configured to allow the spikes to penetrate the aerosol source member.

[0093] In various embodiments, the heating members of the heating assembly 110 can generate heat by receiving electrical energy from an electrical energy source 108. Thus, in some embodiments, the plurality of spikes 112 may comprise a resistive heating member that heats the base material 210 through contact with the base material 210. Because the plurality of spikes 112 extend into a portion of the internal region 208 of the base material 210, the base material 210 in the illustrated embodiment is heated from the inside out. Direct contact may be preferred, given its ability to provide conduction heating that is even faster and requires less thermal resistance. In various embodiments, the plurality of spikes 112 may be constructed from a thermal conductive material. For example, in some embodiments, the plurality of spikes 112 are chemically nonreactive with the material comprising the base material to be heated so as not to adversely affect the flavor or content of the aerosol or vapor produced. As described above, exemplary and non-limiting materials that can contain multiple spikes 112 include carbon, graphite, carbon / graphite composites, metal carbides and non-metal carbides, nitrides, silicides, intermetallic compounds, cermets, and metal alloys. In some embodiments, metal foil may be used.

[0094] In some embodiments, additional heating elements may be used. For example, some additional heating elements may have other shapes corresponding to the shape of the substrate material in the aerosol source element. Other examples of heater arrays that can be adapted for use in this disclosure in accordance with the above description are U.S. Patent No. 5,060,671 by Counts et al., U.S. Patent No. 5,093,894 by Deevi et al., U.S. Patent No. 5,224,498 by Deevi et al., and Sprinkel, which are incorporated herein by reference in their entirety. This can be found in U.S. Patent No. 5,228,460 by Jr. et al., U.S. Patent No. 5,322,075 by Deevi et al., U.S. Patent No. 5,353,813 by Deevi et al., U.S. Patent No. 5,468,936 by Deevi et al., U.S. Patent No. 5,498,850 by Das, U.S. Patent No. 5,659,656 by Das, U.S. Patent No. 5,498,855 by Deevi et al., U.S. Patent No. 5,530,225 by Hajaligol, U.S. Patent No. 5,665,262 by Hajaligol, U.S. Patent No. 5,573,692 by Das et al., and U.S. Patent No. 5,591,368 by Fleischhauer et al.

[0095] Figure 3 shows a schematic perspective view of the heated end 302 of the aerosol source member and a portion of the heating assembly according to another exemplary embodiment of the present disclosure. In particular, the heated end 302 of the aerosol source member defines an outer surface 306 and an internal region 308. In the illustrated embodiment, the base material 310 is located in the internal region 308 of the heated end 302 of the aerosol source member. As described above, in some embodiments, the base material may be located at both the heated end 302 and the mouthpiece end of the aerosol source member. In the illustrated embodiment, the base material 310 has a single segment, but in other embodiments, the base material 310 may include additional segments that may have different compositions. In various embodiments, one or more of the base materials may include tobacco or tobacco-related materials together with the aerosol precursor composition bound thereto. In other embodiments, non-tobacco materials such as cellulose pulp materials may be used. In other embodiments, the non-tobacco base material may not be a plant-derived material. This refers to possible base materials, compositions, components, and / or additives for use with the above base materials (and / or multiple base materials).

[0096] As described above, heating the base material 310 results in the aerosolization of the aerosol precursor composition bound to the base material 310. In various embodiments, the suction end of the aerosol source member is configured to receive the generated aerosol through it in response to suction applied to the suction end by the user. In some embodiments, the suction end of the aerosol source member may include a filter configured to receive the aerosol through it in response to suction applied to the suction end of the aerosol source member. Preferably, the elements of the base material 310 do not undergo significant thermal decomposition (e.g., carbonization, charring, or combustion), and the aerosolized components are taken into the air, which is then drawn into the user's mouth through the aerosol delivery device 100, which includes a filter (if present).

[0097] As shown in Figure 3, the heating assembly of the illustrated embodiment includes a plurality of spikes 112 configured to articulate between a retracted position in which the spikes are not in contact with the aerosol source member and a heating position in which the spikes are in contact with the aerosol source member. In particular, Figure 3 shows the spikes 112 in the heating position. In various embodiments of the heating position, the spikes 112 not only contact the aerosol source member but also penetrate the outer surface 306 of the aerosol source member such that a portion of the spikes 112 extends into the base material 310. In various embodiments, the extent to which the spikes 112 extend into the base material may vary. For example, in some embodiments, the spikes 112 may extend only a small portion into the base material, while in other embodiments, the spikes 112 may extend to the center of the base material 310, and in yet another embodiment, the spikes 112 may penetrate the center of the base material 310.

[0098] In various embodiments, the multiple spikes 112 may comprise opposing rows of spikes 112, as shown in Figure 3, where one row is positioned on one side of the aerosol source member and the other row is positioned on the opposite side of the aerosol source member. Note that in some embodiments, additional rows of spikes 112 may be present, such as three or more rows that can be positioned around the circumference of the heated end 302 of the aerosol source member. However, in other embodiments, a single row of spikes 112 may be present. In some embodiments, the positioning of individual spikes 112 may be staggered between rows, as shown in Figure 3, and in other embodiments, the positioning of individual spikes 112 may be substantially aligned. As described above, in various embodiments, the articulation of the multiple spikes 112 can occur in various ways. For example, in some embodiments, the multiple spikes 112 may be housed in a clamshell housing that moves away from the aerosol source member in the retracted position and toward the aerosol source member in the heated position. In some embodiments, the operation of the articulation may be triggered by a button. For example, in some embodiments, the clamshell housing may be spring-loaded, and a button may be triggered to move the clamshell housing from the retracted position to the heated position. In another embodiment, the user may slide a feature portion that moves one or both of the rows of spikes 112 from the retracted position to the heated position, where the spikes 112 penetrate the outer surface of the base material and enter a portion of its internal region 308.

[0099] In various embodiments, the heating members of a heating assembly can generate heat by receiving electrical energy from an electrical energy source. Thus, in some embodiments, the plurality of spikes 112 may include a resistive heating member that heats the base material 310 via an auxiliary heat-conducting material, in addition to contact with the base material 310. In the illustrated embodiment, the auxiliary heat-conducting material comprises a plurality of spaced conductive bands 320. Thus, in addition to, or as an alternative to, heating of the base material 310 via the spikes 112 themselves, the base material 310 may be heated by the plurality of spaced conductive bands 320 via heat conduction from the plurality of spikes 112. In some embodiments, the plurality of conductive bands 320 may be constructed from a metallic material such as, but not limited to, copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, or any combination thereof. In other embodiments, the plurality of conductive bands 320 may be constructed from a coated metal such as, for example, aluminum-coated copper, or other combinations of coating and base materials selected from the list above. In yet another embodiment, the plurality of conductive bands 320 may be constructed from ceramic materials such as aluminum oxide, beryllium oxide, boron nitride, silicon carbide, silicon nitride, aluminum nitride, or any combination thereof, without limitation. In yet another embodiment, the plurality of conductive bands 320 may be constructed from carbon materials such as graphite, graphene, carbon nanotubes, nanoribbons, diamond-like structured carbon materials, or any combination thereof, without limitation. In yet another embodiment, the plurality of conductive bands 320 may be constructed from polymer composite materials such as polymer materials containing metal, ceramic, or carbon fibers. For example, some embodiments may include polyimide, epoxy, or silicone polymers together with boron nitride, zinc oxide, or alumina fibers. In further embodiments, the present disclosure intends that the plurality of conductive bands 320 may be constructed from composite materials containing any one or any combination of the above materials, or two or more of the above materials.

[0100] Figure 4 shows a schematic perspective view of the heated end 402 of the aerosol source member. Figure 5 shows a schematic perspective view of the heated end 402 of the aerosol source member and a portion of the heating assembly. Figure 6 shows a schematic top view of the heated end of the aerosol source member and a portion of the heating assembly according to another exemplary embodiment of the present disclosure. In the illustrated embodiments, the heated end 402 of the aerosol source member defines a first outer surface 406 and a first internal region 408, and the first base material 410 is located in the first internal region 408 of the heated end 402 of the aerosol source member. As described above, in some embodiments, the base material may be located at both the heated end 402 and the suction end of the aerosol source member. In the illustrated embodiments, the first base material 410 has a single segment, but in other embodiments, the first base material 410 may include additional segments that may have different compositions. In various embodiments, the first base material 410 may include tobacco or tobacco-related materials together with an aerosol precursor composition bound thereto. In other embodiments, non-tobacco materials such as cellulose pulp materials may be used. In other embodiments, the non-tobacco base material may not be a plant-derived material. Possible base materials, compositions for use with the above base materials (and / or multiple base materials), components and / or additives are mentioned.

[0101] The illustrated embodiment also includes a second substrate material 412 substantially surrounding the first substrate material 410. In particular, the second substrate material 412 in the illustrated embodiment is positioned near the first outer surface 406 of the first substrate material 410 and defines its own second outer surface 416 and second internal region 418. Similar to the first substrate material 410, in the illustrated embodiment the second substrate material 412 has a single segment, but in other embodiments the second substrate material 412 may include additional segments which may have different compositions. In various embodiments the second substrate material 412 may include tobacco or tobacco-related material together with an aerosol precursor composition bound thereto. In other embodiments non-tobacco material such as cellulose pulp material may be used. In other embodiments the non-tobacco substrate material may not be plant-derived material. Possible substrate materials, compositions, components and / or additives for use with the above substrate materials (and / or multiple substrate materials) are mentioned. In some embodiments, the first base material 410 and the second base material 412 may contain the same material, but in various other embodiments, the first base material 410 and the second base material 412 may contain different materials. For example, in some embodiments, the first base material 410 and the second base material 412 may each contain one or more components that are desired to be kept separate. For example, in one embodiment, one base material may contain an ionized calcium (e.g., Ca++) component, and the other base material may contain an alginate component.

[0102] As described above, heating the first base material 410 and / or the second base material 412 results in the aerosolization of the aerosol precursor composition bound to the base materials 410, 412. In various embodiments, the suction end of the aerosol source member is configured to receive the generated aerosol through it in response to suction applied to the suction end by the user. In some embodiments, the suction end of the aerosol source member may include a filter configured to receive the aerosol through it in response to suction applied to the suction end of the aerosol source member. Preferably, the elements of the base materials 410, 412 do not undergo significant thermal decomposition (e.g., carbonization, charring, or combustion), and the aerosolized components are taken into the air, which is then drawn into the user's mouth through the aerosol delivery device 100, which includes a filter (if present).

[0103] As shown in Figures 5 and 6, the heating assembly of the illustrated embodiment includes a plurality of spikes 112 configured to articulate between a retracted position in which the spikes 112 are not in contact with the aerosol source member and a heating position in which the spikes 112 are in contact with the aerosol source member. In particular, Figures 5 and 6 show the spikes 112 in the heating position. In various embodiments of the heating position, the spikes 112 not only contact the aerosol source member but also penetrate the second outer surface 416 of the aerosol source member such that a portion of the spikes 112 extends into the second base material 412. In some embodiments, the spikes 112 extend only into the second base material 412 and not into the first base material 410. In such embodiments, the distance to which the spikes 112 extend into the second base material 412 can be variable. For example, in some embodiments, the spike 112 may extend only a short distance within the second base material 412, while in other embodiments, the spike 112 may extend to the center of the second base material 412, and in yet another embodiment, the spike 112 may penetrate the second base material 412. In the illustrated embodiment, the spike 112 penetrates the second base material 412 and further extends into the first base material 410 by penetrating the first outer surface 406. In such embodiments, the extent to which the spike 112 extends into the first base material 410 can be varied. For example, in some embodiments, the spike 112 may extend only a short distance within the first base material 410, while in other embodiments, the spike 112 may extend to the center of the first base material 410, and in yet another embodiment, the spike 112 may penetrate the center of the first base material 410.

[0104] In various embodiments, the multiple spikes 112 may comprise opposing rows of spikes 112, as shown in Figure 5, where one row is positioned on one side of the aerosol source member and the other row is positioned on the opposite side of the aerosol source member. Note that in some embodiments, additional rows of spikes 112 may be present, such as three or more rows that can be positioned around the circumference of the heated end 402 of the aerosol source member. However, in other embodiments, a single row of spikes 112 may be present. In some embodiments, the positioning of individual spikes 112 may be staggered between rows, as shown in Figure 5, and in other embodiments, the positioning of individual spikes 112 may be substantially aligned. As described above, in various embodiments, the articulation of the multiple spikes 112 can occur in various ways. For example, in some embodiments, the multiple spikes 112 may be housed in a clamshell housing that moves away from the aerosol source member in the retracted position and toward the aerosol source member in the heated position. In some embodiments, the operation of the articulation may be triggered by a button. For example, in some embodiments, the clamshell housing may be spring-loaded, and a button may be triggered to move the clamshell housing from the retracted position to the heated position. In another embodiment, the user may slide a feature that moves one or both of the rows of spikes 112 from the retracted position to the heated position, where the spikes 112 penetrate the outer surface of the base material and enter a portion of its internal region 408.

[0105] As described above, in various embodiments, the heating members of the heating assembly can generate heat by receiving electrical energy from an electrical energy source. Thus, in some embodiments, the plurality of spikes 112 may include a resistive heating member that heats the first and second base materials 410, 412 via an auxiliary heat conductive material, in addition to contact with the base materials 410, 412 themselves. In the illustrated embodiment, the auxiliary heat conductive material comprises a plurality of spaced conductive bands 420 positioned between the first outer surface 406 of the first base material 410 and the inner surface of the second base material 412. Thus, in addition to, or as an alternative to, heating of the first and second base materials 410, 412 via the spikes 112 themselves, the first and second base materials 410, 412 may be heated by the plurality of spaced conductive bands 420 via heat conduction from the plurality of spikes 112. In some embodiments, the multiple isolated conductive bands 420 may be constructed from metallic materials such as copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, or any combination thereof, but are not limited. In other embodiments, the multiple conductive bands 420 may be constructed from coated metals such as aluminum-coated copper, or any other combination of coating and base materials selected from the list above. In yet another embodiment, the multiple isolated conductive bands 420 may be constructed from ceramic materials such as aluminum oxide, beryllium oxide, boron nitride, silicon carbide, silicon nitride, aluminum nitride, or any combination thereof, but are not limited. In yet another embodiment, the multiple thermal conductive bands 420 may be constructed from carbon materials such as graphite, graphene, carbon nanotubes, nanoribbons, diamond-like structured carbon materials, or any combination thereof, but are not limited. In yet another embodiment, the multiple thermally conductive bands 420 may be constructed from polymer composite materials such as polymer materials containing metal, ceramic, or carbon fibers, including polyimide, epoxy, or silicone polymers, along with, but not limited to, boron nitride, zinc oxide, or alumina fibers.In further embodiments, the disclosure intends that a plurality of conductive bands may be constructed from any one or any combination of the above materials, or from a composite material comprising two or more of the above materials.

[0106] It should be noted that in the illustrated embodiment, the substrate material is located below and between the conductive bands, but in other embodiments, the aerosol source material may be located only below the conductive bands, or in other embodiments, only between the conductive bands. Furthermore, in the illustrated embodiment, the concentration of the aerosol-generating material in the substrate material is relatively constant throughout the segment, but in some embodiments, the concentration of the aerosol-generating material in the substrate material may vary from segment to segment.

[0107] Figure 7 shows a schematic perspective view of a portion of the heated end 502 of the aerosol source member and a portion of the heating assembly, and Figure 8 shows a schematic top view of the heated end 502 of the aerosol source member and a portion of the heating assembly according to an exemplary embodiment of the present disclosure. In particular, the heated end 502 of the aerosol source member defines a first outer surface 506 and a first internal region 508, and the first base material 510 is located in the first internal region 508 of the heated end 502 of the aerosol source member. As described above, in some embodiments, the base material may be located at both the heated end 502 and the mouthpiece end of the aerosol source member. In the illustrated embodiments, the first base material 510 has a single segment, but in other embodiments, the first base material 510 may include additional segments that may have different compositions. In various embodiments, the first base material 510 may include tobacco or tobacco-related material together with an aerosol precursor composition bound thereto. In other embodiments, non-tobacco material such as cellulose pulp material may be used. In other embodiments, the non-tobacco base material may not be a plant-derived material. Possible base materials, compositions, components, and / or additives for use with the above base materials (and / or multiple base materials) are mentioned.

[0108] The illustrated embodiment also includes a second substrate material 512 substantially surrounding the first substrate material 510. In particular, the second substrate material 512 in the illustrated embodiment is positioned near the first outer surface 506 of the first substrate material 510 and defines its own second outer surface 516 and second internal region 518. Similar to the first substrate material 510, in the illustrated embodiment the second substrate material 512 has a single segment, but in other embodiments the second substrate material 510 may include additional segments which may have different compositions. In various embodiments the second substrate material 512 may include tobacco or tobacco-related material together with an aerosol precursor composition bound thereto. In other embodiments non-tobacco material such as cellulose pulp material may be used. In other embodiments the non-tobacco substrate material may not be plant-derived material. Possible substrate materials, compositions, components and / or additives for use with the above substrate materials (and / or multiple substrate materials) are mentioned. In some embodiments, the first base material 510 and the second base material 512 may contain the same material, but in various other embodiments, the first base material 510 and the second base material 512 may contain different materials. For example, in some embodiments, the first base material 510 and the second base material 512 may each contain one or more components that are desired to be kept separate. For example, in one embodiment, one base material may contain an ionized calcium (e.g., Ca++) component, and the other base material may contain an alginate component.

[0109] As described above, heating of the first base material 510 and / or the second base material 512 results in the aerosolization of the aerosol precursor composition bound to the base materials 510, 512. In various embodiments, the suction end of the aerosol source member is configured to receive the generated aerosol through it in response to suction applied to the suction end by the user. In some embodiments, the suction end of the aerosol source member may include a filter configured to receive the aerosol through it in response to suction applied to the suction end of the aerosol source member. Preferably, the elements of the base materials 510, 512 do not undergo significant thermal decomposition (e.g., carbonization, charring, or combustion), and the aerosolized components are taken into the air, which is then drawn into the user's mouth through the aerosol delivery device 100, which includes a filter (if present).

[0110] As shown in Figures 7 and 8, the heating assembly of the illustrated embodiment includes a plurality of spikes 112 configured to articulate between a retracted position in which the spikes 112 are not in contact with the aerosol source member and a heating position in which the spikes 112 are in contact with a plurality of spaced conductive bands 520 extending around a limited portion of the outer surface of the first base material 510. In particular, Figures 7 and 8 show the spikes 112 in the heating position. In the illustrated embodiment, the plurality of spaced conductive bands 520 function as heating members. In particular, each of the plurality of spaced conductive bands 520 in the illustrated embodiment defines a first end 520a and a second end 520b. Thus, when the plurality of spikes 112 electrically connected to the electrical energy source 108 contact the first and second ends 520a, 520b of each of the plurality of spaced conductive bands 520, a plurality of resistive heating circuits are completed, and as a result, the plurality of spaced conductive bands 520 function as heating members.

[0111] In some embodiments, the plurality of separated conductive bands 520 may be constructed from metallic materials such as copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, or any combination thereof, but are not limited. In other embodiments, the plurality of conductive bands 520 may be constructed from coated metals such as aluminum-coated copper, or any other combination of coating and base materials selected from the list above. In yet another embodiment, the plurality of separated conductive bands 520 may be constructed from ceramic materials such as aluminum oxide, beryllium oxide, boron nitride, silicon carbide, silicon nitride, aluminum nitride, or any combination thereof, but are not limited. In yet another embodiment, the plurality of thermal conductive bands 520 may be constructed from carbon materials such as graphite, graphene, carbon nanotubes, nanoribbons, diamond-like structured carbon materials, or any combination thereof, but are not limited. In further embodiments, the plurality of thermally conductive bands 520 may be constructed from polymer composite materials such as polymer materials containing metal, ceramic, or carbon fibers, including polyimide, epoxy, or silicone polymers, along with boron nitride, zinc oxide, or alumina fibers, but not limited to these. In further embodiments, the disclosure intends that the plurality of conductive bands may be constructed from composite materials containing any one or any combination of the above materials, or two or more of the above materials.

[0112] In some embodiments of the heating position, the spike 112 not only contacts the aerosol source member but also penetrates the second outer surface 516 of the aerosol source member such that a portion of the spike 112 extends into the second base material 512. In some embodiments, the spike 112 extends only into the second base material 512 and not into the first base material 510. In such embodiments, the distance to which the spike 112 extends into the second base material 512 may vary. For example, in some embodiments, the spike 112 may extend only a short distance into the second base material 512, while in other embodiments, the spike 112 may extend to the center of the second base material 512, and in yet another embodiment, the spike 112 may penetrate the second base material 512. For example, in the illustrated embodiment, the spike 112 penetrates the second base material 512 and further penetrates the first outer surface 506 and extends into the first base material 510. In such embodiments, the extent to which the spike 112 extends into the first base material 510 may vary. For example, in some embodiments, the spike 112 may extend only a short distance into the first base material 510, while in other embodiments, the spike 112 may extend to the center of the first base material 510, and in yet another embodiment, the spike 112 may penetrate the center of the first base material 510.

[0113] In various embodiments, the multiple spikes 112 may comprise pairs of spikes 112, such as those shown in Figure 7, where one row is positioned near the other row on the same side of the aerosol source member. In the illustrated embodiments, the rows of spikes 112 are substantially aligned. However, in other embodiments, such as those in which spaced conductive bands have a helical pattern around the base material, the rows of spikes may be staggered. However, it should be noted that in any of the embodiments described herein, it is not necessary to arrange the multiple spikes in a pattern, and therefore, in some embodiments, the multiple spikes may be randomly dispersed. As described above, in various embodiments, the articulation of the multiple spikes 112 can occur in various ways. For example, in some embodiments, the multiple spikes 112 may be housed in a clamshell housing that moves away from the aerosol source member in the retracted position and toward the aerosol source member in the heated position. In some embodiments, the operation of the articulation may be triggered by a button. For example, in some embodiments, the clamshell housing may be spring-loaded, and a button may be triggered to move the clamshell housing from the retracted position to the heated position. In another embodiment, the user may slide a feature that moves one or both of the rows of spikes from the retracted position to the heated position, where the heat-conducting spikes 112 penetrate the outer surface of the substrate material and enter a portion of its internal region 508.

[0114] In any of the embodiments described above, the control component 106 and / or the plurality of spikes 112 may be configured so that the substrate material (e.g., a first substrate material or first and second substrate materials) can be heated within the segment. Thus, the plurality of spikes 112 may be configured to be independently controllable. For example, in some embodiments, individual spikes 112, pairs of spikes 112, and / or groups of spikes 112 may be independently controllable so that different parts of the substrate material can be heated at different times. In one embodiment, individual spikes 112, pairs of spikes 112, and / or groups of spikes 112 may be operated independently so that the substrate material is heated sequentially (e.g., independently articulated and / or independently heated and / or independently connected to an electrical energy source). This can occur via heating from the spikes and / or conductive bands, as described above. In various embodiments, the activation of the spike 112 may be initiated by the consumer's smoke-inhaling action through the use of one or more different sensors, as described separately herein, and / or when smoke-inhalation is stopped as sensed by one or more different sensors, such as a button. Thus, in some embodiments, the number of possible heating segments may correspond to the number of smoke-inhalations available from the aerosol source member 200. In some embodiments, a single aerosol source member may provide about 4 to about 12, about 5 to about 11, or about 6 to about 10 smoke-inhalations.

[0115] The aerosol source components and control bodies of this disclosure may generally be provided together as a complete smoking product or drug delivery article, but it should be noted that these components may also be provided separately. For example, this disclosure also includes disposable units for use with reusable smoking products or reusable drug delivery articles. In certain embodiments, such a disposable unit (which may be an aerosol source component as shown in the accompanying figures) may include a substantially tubular body having a heated end configured to engage with a reusable smoking product or drug delivery article, an opposite mouthpiece end configured to allow an inhalable substance to pass through to a consumer, and walls having outer and inner surfaces defining an internal space. Various embodiments of the aerosol source component (or cartridge) are described in U.S. Patent No. 9,078,473 by Worm et al., which is incorporated herein by reference.

[0116] This disclosure can be further characterized by providing a separate control body for use in reusable smoking products or reusable pharmaceutical delivery articles, in addition to a disposable unit. In certain embodiments, the control body may generally be a housing having a receiving end (which may include a receiving chamber having an open end) for receiving the heated end of a separately provided aerosol source member. The control body may further include an electrical energy source for supplying power to an electrically heated member, which may be a component of the control body or be included in an aerosol source member used with the control unit. In various embodiments, the control body may also include additional components, including a power source (such as a battery), components for activating the flow of current to the heated member, and components for regulating such flow of current to maintain a desired temperature for a desired period of time and / or to cycle or stop the flow of current when the desired temperature is reached or when the heated member is heated for a desired length of time. In some embodiments, the control unit may further include one or more push buttons related to one or both of the components for activating the flow of current to the heated member, and components for regulating such flow of current. The control unit may also include one or more indicators, such as a light indicating that the heater is heating and / or a light indicating the number of smokes remaining in the aerosol source member used with the control unit.

[0117] While the various figures described herein illustrate the operational relationship between the control body and aerosol source component, it should be understood that the control body and aerosol source component may exist as separate devices. Therefore, any further descriptions provided herein regarding the combined components should be understood as applying to the control body and aerosol source component as separate and distinct components.

[0118] In another embodiment, the disclosure may relate to a kit providing various components as described herein. For example, a kit may comprise a control body having one or more aerosol source members. A kit may further comprise a control body having one or more charging components. A kit may further comprise a control body having one or more batteries. A kit may further comprise a control body having one or more aerosol source members and one or more charging components and / or one or more batteries. In a further embodiment, a kit may comprise a plurality of aerosol source members. A kit may further comprise a plurality of aerosol source members and one or more batteries and / or one or more charging components. In the above embodiments, the aerosol source members or control bodies may comprise heating members contained therein. A kit of the present invention may further comprise a case (or other packaging, transport or storage component) that houses one or more of the additional kit components. The case may be a reusable hard container or a soft container. Furthermore, the case may be a mere box or other packaging structure.

[0119] Those skilled in the art, who benefit from the teachings shown in the above description and the associated drawings, will likely envision many modifications and other embodiments of this disclosure. Therefore, it should be understood that this 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. While specific terms are used herein, they are used in a general and descriptive sense only and not for limitation.

Claims

1. an aerosol source member comprising a base material having an aerosol precursor composition bound to an outer surface and an inner region defined thereto, A control body having a housing configured to receive an aerosol source member, An electrical energy source coupled to the housing, A heating assembly operably connected to an electrical energy source, an aerosol delivery device comprising, An aerosol delivery device in which a heating assembly includes a plurality of spikes, the plurality of spikes being configured to articulate between a retraction position in which the plurality of spikes are not in contact with an aerosol source member and a heating position in which the plurality of spikes penetrate the outer surface of a substrate material and enter a portion of its internal region.

2. The aerosol delivery apparatus according to claim 1, wherein the outer surface of the base material includes a plurality of spaced conductive bands.

3. The aerosol delivery apparatus according to claim 2, wherein each of the separated conductive bands surrounds the entire outer surface of the substrate material.

4. The aerosol delivery apparatus according to claim 2, wherein each of the separated conductive bands extends around a limited portion of the outer surface of the substrate material, defining a first end and a second end.

5. The aerosol delivery apparatus according to claim 4, wherein at the heating position, each spike of the plurality of heat conduction spikes is in contact with the first and second ends of the separated conductive bands.

6. The aerosol delivery device according to claim 1, wherein a plurality of spikes comprise a heating member of a heating assembly.

7. The aerosol delivery device according to claim 5, wherein a plurality of spaced conductive bands comprise a heating member of a heating assembly.

8. The aerosol delivery device according to claim 1, wherein the aerosol source member further comprises a second base material defining an outer surface and an internal region, the second base material substantially surrounding the first base material.

9. The aerosol delivery apparatus according to claim 8, wherein the outer surface of the first substrate material includes a plurality of separated conductive bands.

10. The aerosol delivery apparatus according to claim 9, wherein each of the separated conductive bands surrounds the entire outer surface of the substrate material.

11. The aerosol delivery apparatus according to claim 9, wherein each of the separated conductive bands extends around a portion of the outer surface of the substrate material and defines a first end and a second end.

12. The aerosol delivery apparatus according to claim 11, wherein at the heating position, each spike of the plurality of spikes contacts the first and second ends of the separated conductive bands.

13. The aerosol delivery device according to claim 9, wherein a plurality of spikes comprise a heating member of a heating assembly.

14. The aerosol delivery device according to claim 12, wherein a plurality of spaced conductive bands comprise a heating member of a heating assembly.

15. The aerosol delivery device according to claim 1, wherein the base material contains at least one of tobacco material and tobacco-derived material.

16. The aerosol delivery device according to claim 1, wherein the base material contains a non-tobacco material.

17. The aerosol delivery device according to claim 8, wherein the first base material contains the first composition, the second base material contains the second composition, and the first composition is different from the second composition.

18. The aerosol delivery device according to claim 1, wherein the base material contains at least one of the following: fine fragments of tobacco material, beads of tobacco material, extruded structures of tobacco material, compressed sheets of tobacco material, and combinations thereof.

19. The aerosol delivery device according to claim 8, wherein the first base material contains at least one of the following: fine fragments of tobacco material, beads of tobacco material, extruded structures of tobacco material, crimped sheets of tobacco material, and combinations thereof.

20. The aerosol delivery device according to claim 8, wherein the second base material contains at least one of the following: fine fragments of tobacco material, beads of tobacco material, extruded structures of tobacco material, crimped sheets of tobacco material, and combinations thereof.

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