Electric aerosol delivery system

Abstract

The present invention provides an aerosol delivery system comprising a control unit including a first elongated tubular member having a power supply, enabling the user to inhale a flavorful aerosol. [Solution] The cartridge body 200 includes a second tubular member 216 having opposing first and second ends. One of the first and second ends is detachably engaged with one end of the control unit. The cartridge body further comprises a first aerosol generator 212 disposed within the second tubular member, configured to operably engage a power supply with the engagement portion between the control unit and the cartridge body. The second aerosol generator 400 is disposed between the first aerosol generator and the engagement end of the aerosol delivery system, and the second aerosol generator is detachably engaged with the cartridge body or housed within the second tubular member of the cartridge body.

Description

Technical Field

[0001] The disclosure relates to aerosol delivery devices and systems, such as smoking articles, and more particularly to aerosol delivery devices and systems that utilize electrically generated heat for aerosol products (smoking articles are commonly referred to as electronic cigarettes). The aerosol delivery devices and systems may be configured to heat an aerosol precursor, which may be tobacco-based or tobacco-derived, or may incorporate tobacco, but not necessarily, and incorporates materials that can be vaporized to form an inhalable aerosol for a person.

Background Art

[0002] As an improvement or alternative to smoking products that require burning tobacco for use, many smoking devices have been proposed over the years. Many of these devices are said to have been made to provide the sensations associated with tobacco, cigars, or pipes without delivering a significant amount of incomplete combustion and pyrolysis products due to the burning of tobacco. To achieve this goal, numerous smoking products, flavor generators, and medicinal inhalers have been proposed that utilize electrical energy to evaporate or heat volatile substances, or attempt to provide the sensations of tobacco, cigars, or pipes without burning the tobacco to a significant extent. See, for example, the background art of U.S. Patent No. 7,726,320 by Robinson et al., U.S. Patent Application No. 2013 / 0255702 by Griffith, Jr. et al., and U.S. Patent Application Publication No. 2014 / 0096781 by Sears et al., which are incorporated herein by reference. Also, see, for example, various types of smoking articles, aerosol delivery devices, and electric heat sources referred to by the brand names and commercial sources of U.S. Patent Application No. 14 / 170,838 filed on February 3, 2014 by Bless et al., which is incorporated herein by reference.

[0003] It is desirable to provide an electric aerosol delivery system that allows users to inhale a very flavorful aerosol. Furthermore, it may be desirable that the aerosol be delivered in a pleasant and comfortable manner when inhaled into the user's mouth. [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] U.S. Patent Application No. 7,726,320 [Patent Document 2] U.S. Patent Application Publication No. 2013 / 0255702 [Patent Document 3] U.S. Patent Application Publication No. 2014 / 0096781 [Patent Document 4] U.S. Patent Application No. 14 / 170,838 [Overview of the project]

[0005] This disclosure relates to an aerosol delivery system. Such a system can generate an aerosol as a result of heat generated by electricity and deliver the aerosol to be inhaled into the user's mouth. Of particular importance to the aerosol delivery system is to provide tobacco components in aerosol form, as provided to a smoker by devices known or characteristic of e-cigarettes. As used herein, the term “aerosol” includes vapors, gases, aerosols and / or granular forms or granular shapes, whether visible or invisible, in a form considered “smoke-like” or not, that are suitable for human inhalation.

[0006] The above and other requirements, in one aspect, correspond to an aspect of the present disclosure providing an aerosol delivery system. Such an aerosol delivery system may comprise a control body comprising a first elongated tubular member having opposing ends and housing a power source. A cartridge body comprises a second tubular member having opposing first and second ends. One of the first and second ends of the cartridge body removably engages with one of the opposing ends of the control body. The cartridge body further comprises a first aerosol generator disposed within the second tubular member, configured to operably engage a power source with an engagement portion between one of the opposing ends of the control body and one of the first and second ends of the cartridge body. The other of the first and second ends of the cartridge body is further configured as a mouth engagement end. The cartridge body further comprises a second aerosol generator disposed within a second tubular member located between the first aerosol generator and the mouth engagement end. In some embodiments, the second aerosol generating device may further comprise one or more aerosol generating elements, one or more (at least one) aerosol generating elements may be selected from the group consisting of granules, pellets, beads, small discontinuous units, carbon flakes, extruded carbon flakes, ceramic beads, marmerized tobacco flakes, extruded or compressed cylindrical or spherical elements, crushed tobacco flakes, fillers, flavorings, visible aerosol-forming materials, binders, oval elements, irregularly shaped elements, fine fragments, flakes, tobacco-containing elements, visible aerosol-forming material-containing elements, adsorbent substances, absorbent substances, capsules, microcapsules, honeycomb monoliths, single porous structures, and combinations thereof.

[0007] Other aspects of the present disclosure provide a method for forming an aerosol delivery system. Such a method comprises one end of a first elongated tubular member detachably engaging with a first end of a second tubular member, the first elongated tubular member comprising a control unit and having a power supply located inside, and the second tubular member comprising a cartridge body and having a first aerosol generator located inside. The first aerosol generator is configured to operably engage the power supply with an engagement portion between the end of the control unit and the first end of the cartridge body. The method also includes inserting the second aerosol generator into the second tubular member of the cartridge body between the first aerosol generator and the second end of the second tubular member, the second end facing the first end and configured as an engagement end. In some cases, inserting a second aerosol generator into a second tubular member may further comprise one or more aerosol-generating elements within the second tubular member, at least partially forming the second aerosol generator, where one or more (at least one) aerosol-generating elements are selected from the group consisting of granules, pellets, beads, small discontinuous units, carbon flakes, extruded carbon flakes, ceramic beads, marmerized tobacco flakes, extruded or compressed cylindrical or spherical elements, crushed tobacco flakes, fillers, flavorings, visible aerosol-forming materials, binders, oval elements, irregularly shaped elements, fine fragments, flakes, tobacco-containing elements, visible aerosol-forming material-containing elements, adsorbent substances, absorbent substances, capsules, microcapsules, honeycomb monoliths, single porous structures, and combinations thereof. Thus, the present disclosure includes, but is not limited to, the following embodiments.

[0008] Embodiment 1 An aerosol delivery system comprising a control body portion including a first elongated tubular member having opposing ends, a power supply disposed therein, and a cartridge body portion including a second tubular member having opposing first and second ends, wherein one of the first and second ends is detachably engaged with one of the opposing ends of the control body portion, and the cartridge body portion further comprises a first aerosol generator disposed within the second tubular member, and the power supply is configured to operably engage with the engagement between one of the opposing ends of the control body portion and one of the first and second ends of the cartridge body portion, and the other of the first and second ends of the cartridge body portion is further optionally configured as an engagement end, and the cartridge body portion further comprises a second aerosol generator disposed within a second tubular member between the first aerosol generator and the engagement end.

[0009] Embodiment 2 The second aerosol generating device further comprises at least one aerosol generating element, in any of the above or below embodiments, or a combination thereof.

[0010] Embodiment 3 An aerosol delivery system, or any combination thereof, of the embodiments described above or below, wherein at least one aerosol-generating element is selected from the group consisting of granules, pellets, beads, small discontinuous units, carbon flakes, extruded carbon flakes, ceramic beads, marmerized tobacco flakes, extruded or compressed cylindrical or spherical elements, crushed tobacco flakes, fillers, flavorings, visible aerosol-forming materials, binders, oval elements, irregularly shaped elements, fine fragments, flakes, tobacco-containing elements, visible aerosol-forming material-containing elements, adsorbent substances, absorbent substances, capsules, microcapsules, honeycomb monoliths, single porous structures, and combinations thereof.

[0011] Embodiment 4 An aerosol delivery system, or any combination thereof, according to the above or below embodiments, further comprising a first separation element disposed within a second tubular member between a first aerosol generating device and a second aerosol generating device, wherein the first separation element is either thermally conductive or gas-permeable.

[0012] Embodiment 5 An aerosol delivery system, or any combination thereof, of the above or below embodiments, wherein a first separation element extends along a longitudinal axis between opposing ends to define a thickness, and the thickness of the first separation element is configured to separate the second aerosol generator from the heating element of the first aerosol generator.

[0013] Embodiment 6 An aerosol delivery system, or any combination thereof, of the above or below embodiments, further comprising a second separation element disposed within a second tubular member between a second aerosol generating device and a mouth engagement end, wherein the second separation element is either thermally conductive or gas-permeable.

[0014] Embodiment 7 An aerosol delivery system, or any combination thereof, of the above or below embodiments, wherein the second aerosol generating device comprises a cartridge having an elongated tubular body and opposing end members, each of which is either thermally conductive or gas-permeable, the elongated tubular body is further configured to receive at least one aerosol generating element and to cooperate with the opposing end members to house at least one aerosol generating element therein, and the cartridge is configured to be received by the second tubular body.

[0015] Embodiment 8 An aerosol delivery system, or any combination thereof, according to the above or below embodiments, wherein the first aerosol generating device comprises a liquid container located within a second tubular member and is configured to receive an aerosol precursor substance used by the first aerosol generating device to generate the first aerosol.

[0016] Embodiment 9 Any aerosol delivery system of the above or below embodiments, or a combination thereof, wherein the aerosol precursor substance is one of a flavorless agent and an acid-free substance.

[0017] Embodiment 10 Any aerosol delivery system of the above or below embodiments, or a combination thereof, wherein the aerosol precursor substance is one of glycerin, propylene glycol, water, physiological saline, nicotine, an organic acid, and a combination thereof.

[0018] Embodiment 11 Any aerosol delivery system of the above or below embodiments, or a combination thereof, wherein the first aerosol generating device is configured to provide heat for generating a first aerosol, the second aerosol generating device includes at least one aerosol generating element, and at least one aerosol generating element is arranged to interact with a first aerosol drawn through the aerosol generating element to a mouth engagement end in response to heat and suction applied to a mouth engagement end of the cartridge body.

[0019] Embodiment 12 Any aerosol delivery system of the above or below embodiments, or a combination thereof, wherein at least one aerosol generating element of the second aerosol generating device is configured to interact with either heat from a heating element of the first aerosol generating device or a first aerosol generated by the first aerosol generating device for generating a second aerosol.

[0020] Embodiment 13 Any aerosol delivery system of the above or below embodiments, or a combination thereof, wherein the first aerosol generated by the first aerosol generating device is configured to interact with a second aerosol generated by a second aerosol generating device for forming a third aerosol drawn to the mouth engagement end in response to suction applied to the mouth engagement end.

[0021] Embodiment 14 At least one aerosol generation element of the second aerosol generation device interacts with the first aerosol generated by the first aerosol generation device to generate a reinforced aerosol that is drawn into the mouth engagement end in response to suction applied to the mouth engagement end, and is configured to impart a reinforcing substance, any aerosol delivery system of the above or following embodiments, or a combination thereof.

[0022] Embodiment 15 At least one aerosol generation element of the second aerosol generation device interacts with the first aerosol generated by the first aerosol generation device to generate a cooling aerosol that is drawn into the mouth engagement end in response to suction applied to the mouth engagement end, and is configured to remove heat from the first aerosol, any aerosol delivery system of the above or following embodiments, or a combination thereof.

[0023] Embodiment 16 A control body portion including a first elongated tubular member having opposing ends and a power source disposed therein, and a cartridge body portion including a second tubular member having a first opposing end that engages with one of the opposing ends of the control body portion and a second end, the cartridge body portion further comprising a first aerosol generation device disposed within the second tubular member, configured to operably engage the power source at an engagement portion between one of the opposing ends of the control body portion and the first end of the cartridge body portion, and the second end of the cartridge body portion facing towards the mouth engagement end of the aerosol delivery system, and an aerosol delivery system comprising a second aerosol generation device disposed between the first aerosol generation device of the aerosol delivery system and the mouth engagement end and removably engaged with the cartridge body portion or housed within the second tubular member of the cartridge body portion.

[0024] Embodiment 17 An aerosol delivery system according to any of the above or below embodiments, wherein the second aerosol generating device further comprises a plurality of bead or pellet-shaped aerosol generating elements, each containing at least one aerosol-forming material.

[0025] Embodiment 18 An aerosol delivery system according to any of the above or below embodiments, wherein the aerosol-generating element further comprises one or more of granular tobacco, tobacco extract, and nicotine, and the nicotine is in free basic form, salt form, complex, or solvated compound.

[0026] Embodiment 19 An aerosol delivery system according to any of the above or below embodiments, wherein the aerosol-generating element further comprises one or more fillers, binders, flavoring agents, and combinations thereof.

[0027] Embodiment 20 An aerosol delivery system according to any of the above or below embodiments, wherein the aerosol-generating element is fumigated.

[0028] Embodiment 21 An aerosol delivery system according to any of the above or below embodiments, wherein the second aerosol generator is housed within a second tubular member of the cartridge body and includes a plurality of bead or pellet-shaped aerosol generating elements held in place by a first air-permeable separation element positioned within the second tubular member between the first aerosol generator and the second aerosol generator, and a second separation element between the second aerosol generator and the mouth engagement end.

[0029] Embodiment 22 An aerosol delivery system according to any of the above or below embodiments, wherein the second aerosol generator is detachably engaged with a cartridge body and includes a plurality of bead or pellet-shaped aerosol generating elements held in place by a first air-permeable separation element between the first aerosol generator and the second aerosol generator, and a second separation element between the second aerosol generator and the mouth engagement end.

[0030] Embodiment 23 A method for forming an aerosol delivery system, comprising: a first elongated tubular member configured as a control unit and having a power supply located therein; a second tubular member configured as a cartridge body and having a first aerosol generating device located therein; a first aerosol generating element having one end of the first elongated tubular member detachably engaging with the first end of the second tubular member, the first aerosol generating element configured to operably engage the power supply with an engagement portion between one end of the control unit and the first end of the cartridge body; and the second end facing the first end and configured as an engagement end, wherein the second aerosol generating device is inserted into the second tubular member of the cartridge body between the first aerosol generating device and the second end of the second tubular member.

[0031] Embodiment 24 The step of engaging the second aerosol generator with the cartridge body comprises inserting the second aerosol generator into the second tubular member of the cartridge body between the first aerosol generator and the second end of the second tubular member, wherein the second end faces the first end and is configured as an engagement end, in any of the above or below embodiments.

[0032] Embodiment 25 Inserting a second aerosol generating device into a second tubular member further comprises inserting at least one aerosol generating element into the second tubular member, at least partially forming the second aerosol generating device, wherein the at least one aerosol generating element is selected from the group consisting of granules, pellets, beads, small discontinuous units, carbon flakes, extruded carbon flakes, ceramic beads, marmerized tobacco flakes, extruded or compressed cylindrical or spherical elements, crushed tobacco flakes, fillers, flavorings, visible aerosol-forming materials, binders, oval elements, irregularly shaped elements, fine fragments, flakes, tobacco-containing elements, visible aerosol-forming material-containing elements, adsorbent substances, absorbent substances, capsules, microcapsules, honeycomb monoliths, single porous structures, and combinations thereof, in any of the above or below embodiments, or a combination thereof.

[0033] Embodiment 26 Any method or combination thereof of the above or below embodiments, further comprising inserting a first separation element into a second tubular member between a first aerosol generating device and a second aerosol generating device, wherein the first separation element is either thermally conductive or gas-permeable.

[0034] Embodiment 27 Any method or combination thereof of the above or below embodiments further includes inserting a second separation element into a second tubular member between a second aerosol generating device and a mouth engagement end, wherein the second separation element is one of thermally conductive and gas-permeable.

[0035] Embodiment 28 Any method or combination thereof of the above or below embodiments, wherein the second aerosol generator comprises a cartridge having an elongated tubular body and opposing end members, each of which end members is one of thermal conductivity and gas permeability, and the elongated tubular body is further configured to receive at least one aerosol generating element and to house at least one aerosol generating element therein in cooperation with the opposing end members, and inserting the second aerosol generator further comprises inserting the cartridge into the second tubular member of the cartridge body.

[0036] Embodiment 29 A method for forming an aerosol delivery system, comprising: engaging the first end of the second tubular member with one end of the first elongated tubular member, wherein the first aerosol generating element is configured to operably engage the power supply with an engagement portion between one end of the control body and the first end of the cartridge body, and engaging the cartridge body with the second aerosol generating device such that the second end of the cartridge body faces the engagement end of the aerosol delivery system and the second aerosol generating device is positioned between the first aerosol generating device and the engagement end of the aerosol delivery system.

[0037] Embodiment 30 The method according to any of the above or below embodiments, wherein the second aerosol generating apparatus includes a plurality of bead-shaped or pellet-shaped aerosol generating elements held in place by a first air-permeable separation element located in a second tubular member between the first aerosol generating apparatus and the second aerosol generating apparatus, and a second separation element between the second aerosol generating apparatus and the mouth engagement end.

[0038] Embodiment 31 The method, in any of the above or below embodiments, wherein the step of engaging the second aerosol generator with the cartridge body includes detachably engaging the second aerosol generator with the cartridge body, the second aerosol generator comprising a first end configured to detachably engage with the cartridge body and a second end configured to provide a mouth engagement end for an aerosol delivery system, the second aerosol generator comprising a plurality of bead- or pellet-shaped aerosol generating elements held in place by a first air-permeable separation element between the first aerosol generator and the second aerosol generator, and a second separation element between the second aerosol generator and the mouth engagement end.

[0039] Embodiment 32 The method according to any of the above or below embodiments, wherein the second aerosol generating apparatus includes a plurality of bead-shaped or pellet-shaped aerosol generating elements, each containing at least one aerosol-forming material.

[0040] Embodiment 33 The method according to any of the above or below embodiments, wherein the aerosol-generating element further comprises one or more of granular tobacco, tobacco extract, and nicotine, and the nicotine is in free basic form, salt form, complex, or solvated compound.

[0041] Embodiment 34 The aerosol generating element further comprises one or more fillers, binders, flavoring agents, and combinations thereof, in any of the above or below embodiments.

[0042] Embodiment 35 The method, either of the above or the following embodiments, wherein the aerosol-generating element is subjected to fumigation.

[0043] Embodiment 36 Aerosol delivery system comprising: a control unit including a first elongated tubular member having opposing ends and a power supply disposed therein; a cartridge body including a second tubular member having opposing first and second ends, the first end of which engages with one of the opposing ends of the control unit; the cartridge body further comprising a first aerosol generator disposed in the second tubular member, configured to operably engage the power supply by engagement between one of the opposing ends of the control unit and the first end of the cartridge body, the second end of which faces the mouth engagement end of the aerosol delivery system; and a second aerosol generator disposed between the first aerosol generator and the mouth engagement end of the aerosol delivery system, which is detachably engaged with the cartridge body or housed in the second tubular member of the cartridge body, wherein the second aerosol generator further comprises a plurality of bead-shaped or pellet-shaped aerosol generating elements.

[0044] Embodiment 37 The second aerosol generating device comprises an external housing body and a plurality of stackable, gas-permeable containers within the external housing body, each container containing a plurality of aerosol generating elements, in any aerosol delivery system or combination thereof as described above or below.

[0045] Embodiment 38 The second aerosol generating device comprises an external housing body and an internal compartment subdivided into a plurality of subcompartments, each subcompartment containing a plurality of aerosol generating elements, in any of the above or below embodiments, or a combination thereof.

[0046] Embodiment 39 Any aerosol delivery system or combination thereof according to the above or below embodiments, wherein the beads or pellets comprise a substrate material selected from the group consisting of glass beads, fibers, honeycomb structures, porous monoliths, and polymer beads.

[0047] Embodiment 40 An aerosol delivery system, or any combination thereof, of the above or below embodiments, in which each bead or pellet is in the form of an extruded material comprising granular material selected from tobacco material and filler, at least one aerosol-forming material, and at least one binder.

[0048] Embodiment 41 An aerosol delivery system, or any combination thereof, of the above or below embodiments, wherein the aerosol-generating element further comprises one or more flavoring agents.

[0049] These and other features, aspects and advantages of this disclosure will become clearer upon reading the following detailed description, along with the accompanying drawings which are briefly described below. This disclosure includes any combination of two, three, four or more of the above-described aspects, and any combination of two, three, four or more features or elements described in this disclosure, whether or not they are expressly combined in the description of any particular embodiment herein. This disclosure is intended to be read as a whole so that any separable feature or element of the disclosed invention should be considered to be intended to be combinable in any of its various aspects and embodiments, unless there is an express indication in the context that it is not.

[0050] Having explained the disclosure in general terms as described above, I will now refer to the attached drawings, but please note that they are not necessarily drawn to a fixed scale. [Brief explanation of the drawing]

[0051] [Figure 1] This is a schematic diagram of an aerosol delivery device, including a cartridge body shown in an exploded configuration and a control unit shown in an assembled configuration, according to an exemplary embodiment of the present disclosure. [Figure 2] This is a schematic diagram of the control unit shown in Figure 1 in an exploded configuration according to an exemplary embodiment of the present disclosure. [Figure 3] Figure 1 is a schematic diagram of a cartridge body that implements an additional aerosol generating device including one or more aerosol generating elements, according to an exemplary embodiment of the present disclosure. [Figure 4] Figure 3 is a schematic diagram of an additional aerosol generator, configured as a cartridge containing one or more aerosol-generating elements, according to another aspect of the present disclosure. [Figure 5] This is a schematic exploded view of an alternative carbon-based cartridge body according to an exemplary embodiment of the present disclosure. [Figure 6A] Figure 5 is a schematic assembly diagram of the carbon-based cartridge body according to an exemplary embodiment of the present disclosure. [Figure 6B]This is a schematic assembly diagram of a carbon-based cartridge body that implements an additional aerosol generator, which includes one or more aerosol generating elements, according to one aspect of the present disclosure. [Figure 7] This is a cross-sectional view of a second aerosol generator housed in the same external body as the first aerosol generator according to an exemplary embodiment of the present disclosure. [Figure 8] This is a cross-sectional view of a second aerosol generator, which is detachably attached to an external body housing a first aerosol generator according to an exemplary embodiment of the present disclosure. [Figure 9] This is a cross-sectional view of a second aerosol generator comprising multiple stackable components. [Figure 10] This is a top view of an aerosol generating device with multiple wedge-shaped components. [Modes for carrying out the invention]

[0052] Herein, this disclosure is best described below with reference to exemplary embodiments. These exemplary embodiments are best described in order to complete this disclosure and will best convey the scope of this disclosure to those skilled in the art. Indeed, this disclosure may be embodied in many different forms and should not be construed as being limited to the embodiments described herein, but rather these embodiments are provided to satisfy the legal requirements to which this disclosure is applicable. Where used herein and in the appended claims, the singular forms “a”, “an”, and “the” shall be plural unless the context clearly indicates otherwise.

[0053] As described below, aspects of the present disclosure relate to aerosol delivery systems. The aerosol delivery systems according to the present disclosure use electrical energy to heat a material (preferably the material is burned to a not very high degree) for forming an inhalable substance, and the components of such a system are articles that are small enough in shape to be most preferable for such a system which is considered to be handheld. That is, by using components of a preferred aerosol delivery system, the aerosol does not result in smoke generation in the sense that it is primarily derived from byproducts of the combustion or pyrolysis of tobacco, and these preferred systems result in vapor generation (including vapor in the aerosol which may be considered a visible / invisible aerosol which may be described as smoke-like) derived from the volatilization or vaporization of a predetermined component incorporated therein. In preferred embodiments, the components of the aerosol delivery system may be characterized as an e-cigarette, which most preferably incorporates tobacco and / or components derived from tobacco and thus delivers tobacco derived from the component in aerosol form.

[0054] An aerosol-generating piece of a given preferred aerosol delivery system may provide much of the sensation of smoking a tobacco, cigar, or pipe (e.g., the ritual of inhalation and exhalation, type of flavor or taste, sensory effects, physical sensations, ritual of use, visual stimuli, such as those provided by a visible aerosol) by igniting and burning a tobacco (and thus inhaling tobacco smoke) without substantially burning any of its components. For example, a user of the aerosol-generating piece of the present disclosure can hold and use one piece in the same way a smoker uses a traditional smoking article, inhaling one end of the piece to inhale the aerosol produced by the piece, and taking puffs at chosen time intervals.

[0055] Furthermore, the aerosol delivery systems of this disclosure may be characterized as suitable vapor products, aerosol products, or drug delivery articles. Thus, such articles, systems, or devices may be configured to deliver one or more substances (e.g., flavors, pharmaceutically active ingredients, peptides, protein fragments, and / or protein membranes) in an inhalable form or state. For example, the inhalable substance may be substantially in vapor form (i.e., a substance that is in the gas phase at temperatures below its critical point). Alternatively, the inhalable substance may be in aerosol form (i.e., a suspension of solid particles or droplets in a gas). For simplicity, as used herein, the term “aerosol” includes vapors, gases, aerosols, and / or granular forms or granular shapes that are suitable for human inhalation, whether visible or invisible, and whether considered “smoky” or not.

[0056] The aerosol delivery system of the present disclosure most preferably comprises several combinations of a power source (i.e., a power source), at least one control component (means for operating, controlling, regulating and / or terminating the power supplied for heat generation, such as by controlling the flow of current from a power discharger to other components of the aerosol generator), a heating component or heat generating component (e.g., an electrical resistance heating element and associated components commonly referred to as providing a "sprayer"), an aerosol precursor composition (e.g., a component that is generally liquid and capable of generating an aerosol with sufficient heat, such as a component commonly referred to as "smoke juice," "e-liquid," or "e-juice"), and a mouth end region, mouth engagement end or mouth engagement to enable suction on the aerosol delivery system for aerosol suction (e.g., a defined airflow path through an aerosol generator from which the generated aerosol can be drawn in by suction).

[0057] More specific forms, configurations, and arrangements of components in the aerosol delivery system of this disclosure are provided below. Furthermore, the selection and arrangement of various aerosol delivery system components can be understood by considering commercially available electronic aerosol delivery devices, such as the representative products referenced in the background art of this disclosure.

[0058] In some embodiments, the use of the aerosol delivery device of the Disclosure may involve many of the actions taken by an individual using a traditional type of smoking article. For example, a user of the aerosol delivery device of the Disclosure may hold the article like a traditional smoking article, inhale one end of the article to inhale the aerosol produced by the article, and take a puff at selected time intervals or for a selected period of time.

[0059] An example of such an aerosol delivery system is shown in Figure 1. Specifically, Figure 1 shows a partially exploded view of an aerosol delivery system 100 including a cartridge body 200 and a control unit 300 (or, as referred to herein, the “cartridge body” and the “control unit,” respectively). The cartridge body 200 and the control unit 300 may be permanently or detachably aligned or detachably engaged in an operating relationship. Various mechanisms may be used to connect the cartridge body 200 to the control unit 300, resulting in screw-fit, press-fit, snap-fit, magnetic engagement, and the like. When the cartridge body 200 and the control unit 300 are in an assembled configuration, the aerosol delivery system 100 may, in some embodiments, be substantially rod-shaped, substantially tubular, or cylindrical. As used herein, “tubular” refers to a hollow, elongated body, but is not limited to a specific cross-sectional shape or a specific external contour of the body. Furthermore, peers will understand that, in some cases, although not described in detail herein, the cartridge body 200 and control body 300 forming the aerosol delivery system 100 may be composed of single, non-detachable pieces and may incorporate the components, aspects and features disclosed herein in relation to the present disclosure.

[0060] In some examples, either or both of the cartridge body 200 and the control unit 300 may be referred to as disposable (i.e., single-piece, non-removable as previously disclosed) or reusable. For example, a reusable control unit 300 may use a replaceable battery or a rechargeable battery and thus be combined with any type of charging technology, including connection to a typical AC outlet, connection to a vehicle charger (i.e., cigarette lighter socket), and connection to a computer such as via a Universal Serial Bus (USB). Generally, the types of aerosol delivery systems disclosed herein incorporate a battery or other power source to provide sufficient current to the article to perform various functions, such as powering a heater or heating element, powering a control system, powering an indicator, etc. The power source can take various embodiments. Preferably, the power source delivers enough power to rapidly heat the heating element and to provide for aerosol formation and operation of the article for the duration of use. The power source is preferably sized to fit conveniently into the aerosol delivery device / system so that the aerosol delivery device / system can be easily operated, and further, the preferred power source is preferably light enough not to impair the desired smoking experience. In addition, in some cases, the cartridge body 200 may include a single-use cartridge (i.e., disposable) as disclosed, for example, in U.S. Patent Application Publication 2014 / 0060555 by Chang et al., which is incorporated herein by reference in its entirety.

[0061] Figure 2 shows an exploded view of the control unit 300 of an aerosol delivery system 100 according to another example. As shown, the control unit 300 comprises a coupler 302, an external body 304, a sealing member 306, an adhesive member 308 (e.g., KAPTON® tape), a flow sensor 310 (e.g., a puff sensor or pressure switch), control components 312, a spacer 314, a power source 316 (e.g., a battery-rechargeable one), a circuit board 318 with an indicator (e.g., a light-emitting diode (LED)), a connector circuit 320, and an end cap 322. An example of a power source is described in U.S. Patent Application Publication 2010 / 0028766 by Pecherar et al., which is incorporated herein by reference in its entirety.

[0062] With respect to the flow sensor 310, typical current regulating components and other current control components, including various microcontrollers, sensors and switches for aerosol delivery devices / systems, are incorporated herein by reference, for example, U.S. Patent Publication No. 4,735,217 by Gerth et al., No. 4,947,874 by Brooks et al., No. 5,372,148 by McCafferty et al., No. 6,040,560 by Fleischhauer et al., No. 7,040,314 by Nguyen et al., and No. 8,205,622 by Pan et al., U.S. Patent Publication No. 2009 / 0230117 by Fernando et al., No. 2014 / 0060554 by Collett et al., No. 2014 / 0270727 by Ampolini et al., and U.S. Patent Application No. 14 / 209,191 filed March 13, 2014 by Henry et al.

[0063] In some examples, the indicator 318 may include one or more light-emitting diodes. The indicator 318 communicates with a control component 312 via a connector circuit 320 and may light up while the user is sucking on the cartridge body 200 coupled to the coupler 302, for example, as detected by a flow sensor 310. The end cap 322 may be such that it visualizes the illumination provided by the indicator 318. Thus, the indicator 318 may light up during use of the aerosol delivery system 100 and mimic the lit end of a smoking article. However, in other examples, the indicator 318 may be provided with various numbers, may take different shapes, and may be an opening in the external body (for example, to emit sound if such an indicator is present). Further representative types, configurations, and uses of indicators, such as components that produce visual stimuli or light-emitting diode (LED) components, are described in U.S. Patent No. 5,154,192, Newton No. 8,499,766, and Scatterday No. 8,539,959, as well as in U.S. Patent Application No. 14 / 173,266, filed February 5, 2014, by Sears et al., which are incorporated herein by reference.

[0064] Furthermore, features, controls, and components that can be incorporated into the aerosol delivery devices and systems of this disclosure include those of Harris et al. (US Patent No. 5,967,148), Watkins et al. (US Patent No. 5,934,289), Counts et al. (US Patent No. 5,954,979), Fleischhauer et al. (US Patent No. 6,040,560), Robinson et al. (US Patent No. 7,726,320), Hon et al. (US Patent No. 8,365,742), Fernando et al. (US Patent Application Publication No. 8,689,804), Tucker et al. (US Patent Application Publication No. 2013 / 0192623), Leven et al. (US Patent No. 2013 / 0298905), Kim et al. (US Patent No. 2013 / 0180553), Sebastian et al. (US Patent Application Publication No. 2014 / 0000638), Novak This is described in U.S. Patent Application Publication 2014 / 0161495 and DePiano's 2014 / 0261408, among others.

[0065] Returning to Figure 1, the cartridge body 200 is shown in an exploded configuration. As shown, according to exemplary embodiments of the present disclosure, the cartridge body 200 may include a base shipping plug 202, a base 204, control component terminals 206, electronic control components 208, a flow tube 210, a sprayer 212, a reservoir substrate 214, an outer body 216, a label 218, a mouthpiece 220, and a mouthpiece shipping plug 222. The base 204 is coupled to a first end of the outer body 216, and the mouthpiece 220 is coupled to an opposing second end of the outer body 216, and can house the remaining components of the cartridge body 200. The base 204 may be configured to detachably engage with a coupler 302 of the control unit 300. In some examples, the base 204 may have an anti-rotation feature that substantially prevents relative rotation between the cartridge body and the control body, as disclosed in U.S. Patent Application Publication 2014 / 0261495, et al., Novak III, which is incorporated herein by reference in its entirety. Various typical coupling mechanisms for the upstream and downstream components of e-cigarettes have been described in the patent literature and have been employed in the production of commercially available e-cigarettes. For example, typical coupling mechanisms for e-cigarettes are described in U.S. Patent Application Publication 2014 / 0261495, et al., Novak III, and U.S. Patent Application No. 14 / 170,838, filed February 3, 2014, by Bless et al., which are incorporated herein by reference.

[0066] The base shipping plug 202 may be configured to engage with the base 204 before use of the cartridge body 200 and protect the base 204. Similarly, the mouthpiece shipping plug 222 may be configured to engage with the mouthpiece 220 before use of the cartridge body 200 and protect the mouthpiece 220. Control component terminals 206, electronic control components 208, flow tube 210, atomizer 212, and reservoir substrate 214 (which engages with the aerosol precursor composition or aerosol precursor substance) may be held within the outer body 216. A label 218 may surround the outer body 216 at least partially and contain information such as a product identification name.

[0067] The arrangement of components in either or both the control body and the cartridge body of the aerosol delivery device and system may be modified. In specific embodiments, the aerosol precursor composition may be located near one end of the whole article (e.g., in a cartridge body which may be replaceable and disposable under certain circumstances), and may be configured to be located relatively close to the user's mouth to maximize the delivery of the aerosol to the user. However, other configurations are not excluded. Generally, the heating element is located close enough to the aerosol precursor composition so that heat from the heating element can volatilize the aerosol precursor (and / or one or more flavoring agents, drugs, etc. which may be similarly provided for delivery to the user) and form an aerosol to be delivered to the user. When the heating element heats the aerosol precursor composition, the aerosol is formed, emitted, and generated in a physical form suitable for inhalation by the consumer. Note that the aforementioned terms meaning emitting, emitting, emitting (third person), or emitted include emitting or generating, forming or generating, and formed or generated, and mean replaceable. Specifically, the aspirable substance is emitted in the form of vapor, aerosol, or a mixture thereof. Furthermore, the selection of various aerosol delivery device components can be understood by considering commercially available electronic aerosol delivery devices, such as the representative products described above in this disclosure.

[0068] The atomizer (i.e., aerosol generator) 212 may include a first heating terminal 234a and a second heating terminal 234b, a liquid transport element 238, and a heating element 240. In this regard, the reservoir and / or reservoir substrate 214 may be configured to hold the aerosol precursor composition. The aerosol precursor composition, also called the vapor precursor composition, may, in different embodiments, contain a variety of components. For example, such components may include any of the following: polyhydric alcohols (e.g., glycerin, propylene glycol or a mixture thereof), nicotine, tobacco, tobacco extract, water, flavoring agents, or combinations thereof.

[0069] The aerosol precursor or the precursor composition described above may vary. It is most preferable that the aerosol precursor composition consists of a combination or mixture of various components or constituents. The selection of specific aerosol precursor components and the relative amounts of these components used may be modified to control the overall chemical composition of the mainstream aerosol produced by the aerosol generator. Of particular importance to the aerosol precursor composition is that it can essentially be characterized as a liquid in general. For example, a typical aerosol precursor composition may be in the form of a solution, a viscous gel, a mixture of miscible components, or a liquid incorporating suspended or dispersed components. A typical aerosol precursor composition is evaporable when exposed to heat under the conditions in which it is placed during use of the aerosol generator, a feature of this disclosure, and is therefore capable of producing aspirable vapor and aerosol.

[0070] In an aerosol delivery system characterized as an e-cigarette, it is most preferable that the aerosol precursor composition incorporates tobacco or tobacco-derived components. On the one hand, tobacco may be provided as part or piece of tobacco, such as finely ground, crushed, or powdered tobacco flakes. On the other hand, tobacco may be provided in an extract form, such as a spray-dried extract, incorporating many of the water-soluble components of tobacco. Alternatively, the tobacco extract may be in the form of a relatively high nicotine-containing extract, which also incorporates smaller amounts of other tobacco-derived extractants. On the other hand, tobacco-derived components that are highly produced or used in an essentially pure form include nicotine (e.g., pharmaceutical-grade nicotine).

[0071] As described above, highly purified tobacco-derived nicotine (e.g., pharmaceutical-grade nicotine with a purity of over 98% or 99%) or derivatives thereof may be used in the present invention. A typical nicotine-containing extract may be provided using the technique described in U.S. Patent No. 5,159,942 by Brinkley et al., incorporated herein by reference. In some embodiments, the products of the present invention may contain any form of nicotine from any source, whether tobacco-derived or synthetic. The nicotine compound used in the products of the present invention may include nicotine in free basic form, salt form, complex, or solvated compound form. See, for example, the discussion of free basic form nicotine in U.S. Patent Publication 2004 / 0191322 by Hansson, incorporated herein by reference. At least a portion of the nicotine compound may be employed in the form of a nicotine resin complex in which nicotine is bound to an ion exchange resin such as nicotine polarilex. See, for example, U.S. Patent No. 3,901,248 by Lichtneckert et al., incorporated herein by reference. At least a portion of the nicotine may be used in salt form. Nicotine salts may be provided using the component types and techniques described in U.S. Patent No. 2,033,909 (Cox, etc.) and Perfetti, Beitrage Tabakforschung Int., 12 43–54 (1983). Furthermore, nicotine salts have been obtained from sources such as Pfaltz and Bauer, Inc. and K&K Laboratories, Division of ICN Biochemicals, Inc. Exemplary pharmaceutically acceptable salts of nicotine include salts of nicotine such as tartrates (e.g., nicotine tartrate and nicotine hydrogen tartrate), chlorides (e.g., nicotine hydrochloride and nicotine hydrochloride), sulfates, perchlorates, ascorbyl hydrochloride, fumarates, citrates, malates, lactates, aspartates, salicylates, tosylates, succinates, pyruvates, and nicotine salt hydrates (e.g., nicotine zinc chloride hydrate).In some embodiments, at least a portion of the nicotine component is in the form of a salt comprising an organic acid moiety, including but not limited to levulinic acid, as discussed in U.S. Patent Publication 2011 / 0268809, Brinkley et al., incorporated herein by reference.

[0072] Furthermore, the aerosol precursor composition may incorporate a so-called "aerosol-forming material." In some examples, such a material has the function of generating a visible (or invisible) aerosol when it evaporates when exposed to heat under conditions that occur during normal use of an aerosol generator specific to this disclosure. Such aerosol-forming materials include various polyols or polyhydric alcohols (e.g., glycerin, propylene glycol, and mixtures thereof). Also, aspects of this disclosure incorporate aerosol precursor components characterized as water, physiological saline, water vapor, or aqueous liquid. During normal use of some aerosol generators, water incorporated into these aerosol generators may evaporate to produce components of the generated aerosol. Therefore, for the purposes of this disclosure, water present in the aerosol precursor composition may be considered the aerosol-forming material.

[0073] It is possible to employ any flavoring or material of a wide variety that modifies the functional characteristics or properties of the inhaled mainstream aerosol produced by the aerosol delivery system of this disclosure. For example, any such flavoring may be used in the aerosol precursor composition or in the aerosol precursor substance to modify the flavor, aroma, and functional properties of the aerosol. Some flavorings may be provided from sources other than tobacco. Exemplary flavorings may be essentially natural or artificial and may be employed as concentrates or flavor packages.

[0074] Exemplary flavorings include 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 aroma packages of types and characteristics traditionally used for flavoring tobacco, cigars, and pipe tobacco. Syrups such as high-fructose corn syrup may also be used. A predetermined flavoring may be incorporated into the aerosol-forming material before the formation of the final aerosol precursor mixture (for example, a predetermined water-soluble flavoring may be incorporated into water, menthol may be incorporated into propylene glycol, or a predetermined complex flavor package may be incorporated into propylene glycol). However, in some aspects of this disclosure, the aerosol precursor composition does not contain any flavoring agents, flavor properties, or additives.

[0075] Furthermore, the aerosol precursor composition may contain components that exhibit acidity or basic properties (e.g., organic acids, ammonium salts, or organic amines). For example, a predetermined organic acid (e.g., levulinic acid, succinic acid, lactic acid, and pyruvic acid) may be included in the formation of the nicotine-incorporating aerosol precursor up to an equimolar amount (based on the total organic acid content) preferably containing nicotine. For example, the aerosol precursor may contain about 0.1 to 0.5 moles of levulinic acid, about 0.1 to 0.5 moles of succinic acid, about 0.1 to 0.5 moles of lactic acid, about 0.1 to 0.5 moles of pyruvic acid, or various permutations and combinations thereof, per mole of nicotine, up to a concentration equimolar to the total amount of nicotine present in the aerosol precursor composition. However, in some aspects of this disclosure, the aerosol precursor composition does not contain any acidic (or basic) properties or additives.

[0076] As a non-limiting example, a typical aerosol precursor composition or aerosol precursor substance may contain glycerin, propylene glycol, water, physiological saline, nicotine, and any combination or mixture of any or all of these components. For example, in one example, a typical aerosol precursor composition may contain about 70% to 100% glycerin, about 80% to 90% glycerin, about 5% to 25% water, often about 10% to 20% water, and about 0.1% to 5% nicotine, often about 2% to 3% nicotine (by weight). As a specific non-limiting example, a typical aerosol precursor composition may contain 84% glycerin, 14% water, and 2% nicotine. A typical aerosol precursor composition may also contain propylene glycol, any flavorings, or other additives, in amounts varying by weight. In some examples, an aerosol precursor composition may contain up to about 100% by weight of any of glycerin, water, or physiological saline, as needed or desired.

[0077] Furthermore, typical types of aerosol precursor components and aerosol precursor formation are described and characterized in U.S. Patent Publication No. 7,217,320 by Robinson et al., and U.S. Patent Publication No. 2013 / 0008457 by Zheng et al., No. 2013 / 0213417 by Chong et al., and No. 2014 / 0060554 by Collett et al., the disclosure of which is incorporated herein by reference. Other aerosol precursors that may be used include aerosol precursors incorporated into RJReynolds Vapor Company's VUSE® products, Lorillard Technologies' BLU™ products, Mistic Ecigs' the MISTIC MENTHOL products, and CN Creative Ltd.'s VYPE products. Also desirable are the so-called "smoke juices" for e-cigarettes available from Johnson Creek Enterprise LLC.

[0078] The amount of aerosol precursor incorporated into the aerosol delivery system is such that the aerosol generator provides the desired performance characteristics and feel that meet the requirements. For example, it is highly preferable that a sufficient amount of aerosol-forming material (e.g., glycerin and / or propylene glycol) is employed to provide for the generation of a mainstream aerosol (visible or invisible) that in many respects resembles the appearance of cigarette smoke. The amount of aerosol precursor composition in the aerosol generator may depend on factors such as the desired number of inhalations for each aerosol generator. Typically, the amount of aerosol precursor composition incorporated into the aerosol delivery system and specifically into the aerosol generator is less than about 2 g, generally less than about 1.5 g, often less than about 1 g, and frequently less than 0.5 g.

[0079] The reservoir substrate 214 may comprise a multi-layer nonwoven fiber product formed in a cylindrical shape that surrounds the inside of the outer body 216 of the cartridge body 200. Thus, for example, a liquid component can be adsorbed by the reservoir substrate 214. The reservoir substrate 214 is fluidly connected to a liquid transport element 238. The liquid transport element 238 may be configured to transport the liquid (i.e., the aerosol precursor composition) from the reservoir substrate 214 to the heating element 240 via capillary action. Typical types of substrates, reservoirs, or other components for supporting the aerosol precursor composition are described by reference herein in U.S. Patent Application Publication No. 8,528,569 by Newton, U.S. Patent Application Publication No. 2014 / 0261487 by Chapman et al., and No. 2015 / 0059789 by Davis et al., and U.S. Patent Application No. 14 / 170,838 filed February 3, 2014 by Bless et al. Furthermore, various wicking materials and the configuration and operation of wicking materials in a given type of e-cigarette are described in U.S. Patent Application Publication 2014 / 0209105 by Sears et al., which is incorporated herein by reference.

[0080] As shown in the figure, the liquid transport element 238 may be in direct contact with the heating element 240. Furthermore, as shown in Figure 1, the heating element 240 may include wires defining a plurality of coils wound around the liquid transport element 238. In some examples, the heating element 240 may be formed by winding wires around the liquid transport element 238 as described in U.S. Patent Application Publication 2014 / 0157583, Ward et al., which is incorporated herein by whole reference. Furthermore, in some examples, the wires may define a variable coil spacing as described in U.S. Patent Application Publication 2014 / 0270730, DePiano et al., which is incorporated herein by whole reference. Various materials configured to generate heat when an electric current is applied may be employed to form the heating element 240. Examples of materials that can form wire coils include Kanthal (FeCrAl), nichrome, molybdenum disilicide (MoSi2), molybdenum silicide (MpoSi2), aluminum-added molybdenum disilicide (Mo(Si,Al)2), graphite and graphite-based materials, and ceramics (e.g., positive temperature coefficient ceramics or negative temperature coefficient ceramics).

[0081] However, various other methods may be employed to form the heating element 240, and various other embodiments of the heating element may be employed in the sprayer 212. For example, a punched heating element may be employed in the sprayer as described in U.S. Patent Application Publication 2014 / 0270729 by DePiano et al., which is incorporated herein by reference in its entirety. Following the foregoing, further representative heating elements and heating materials used in sprayers are described in U.S. Publication No. 5,060,671, U.S. Publication No. 5,093,894, U.S. Publication No. 5,224,498, U.S. Publication No. 5,228,460, U.S. Publication No. 5,322,075, U.S. Publication No. 5,353,813, U.S. Publication No. 5,498,850, U.S. Publication No. 5,659,656, U.S. Publication No. 5,498,855, U.S. Publication No. 5,530,225, U.S. Publication No. 5,665,262, U.S. Publication No. 5,573,368, and U.S. Publication No. 5,591,368, the disclosures of which are incorporated herein by reference in their entirety. Furthermore, chemical heating may be employed in other embodiments. Furthermore, various heating elements may be used in specific embodiments of the aerosol delivery device / system. In various examples, one or more microheaters or similar solid-state heating elements may be used. Exemplary microheaters that may be available are further described herein. In addition, a microheater and a sprayer incorporating a microheater suitable for use in the aerosol delivery device / system of the present disclosure are described in U.S. Patent Application Publication 2014 / 0060554 by Collett et al., which is incorporated herein by reference in its entirety.

[0082] When the cartridge body 200 is coupled to the control unit 300, the first heating terminals 234a and the second heating terminals 234b (e.g., positive and negative terminals) at the opposing ends of the heating element 240 are configured to form an electrical connection (removable connection) with the control unit 300. Furthermore, when the control unit 300 is coupled to the cartridge body 200, an electronic control component 208 may form an electrical connection with the control unit 300 via the control component terminal 206. Thus, the control unit 300 may employ the electronic control component 208 to determine whether the cartridge body 200 is genuine and / or to perform other functions. Furthermore, various examples of electronic control components and the functions they perform are described in U.S. Patent Application Publication 2014 / 0096781 by Sears et al., which is incorporated herein by reference in its entirety.

[0083] During use, the user may inhale through the mouthpiece or mouth engagement end 220 of the cartridge body 200 of the aerosol delivery system 100. This may draw air through the control body 300 and / or the opening of the cartridge body 200. For example, in one embodiment, as described in U.S. Patent Application Publication 2014 / 0261408 by DePiano et al., which is incorporated herein by reference in its entirety, the opening may be defined between the coupler 302 and the outer body 304 of the control body 300. However, in other embodiments, the airflow may be received through other parts of the aerosol delivery device / system 100. As described above, in some embodiments, the cartridge body 200 may include a flow tube 210. The flow tube 210 may be configured to guide the airflow received from the control body 300 to the heating element 240 of the atomizer 212.

[0084] A sensor in the aerosol delivery device / system 100 (e.g., a puff sensor or flow sensor in the control unit 300) may detect ingestion. More generally, when aerosol generation is desired (e.g., for inhalation during use), a sensor or detector may be implemented to control the supply of current to the heating element 240. Thus, methods or techniques are provided for, for example, stopping the power supply to the heating element 240 when aerosol generation is not desired during use, and for supplying power to activate or induce heat generation by the heating element 240 during inhalation. Further representative types of sensing or detection mechanisms, structures and configurations of the aerosol delivery device / system 100, their components and general methods of operation are described herein by reference in U.S. Patent No. 5,261,424 by Sprinkel, Jr., McCafferty et al., No. 5,373,148 and PCT International Publication No. WO2010 / 003480 by Flick. When ingestion is detected, the control unit 300 may direct a current to the heating element 240 via a circuit including a first heating terminal 234a and a second heating terminal 234b. Thus, the heating element 240 may evaporate the aerosol precursor composition that has been guided from the reservoir substrate 214 to the aerosolization region by the liquid transport element 238. The mouthpiece 220 may thereby allow the passage of air and accompanying vapor from the cartridge body 200 to the consumer's inhalation location on the cartridge body. Various other details regarding components that may be included in the cartridge body 200 are provided, for example, in U.S. Patent Application Publication 2014 / 0261495, such as Novak III, which is incorporated herein by reference in its entirety.

[0085] Various components of the aerosol delivery device / system may be selected from components described by peers and commercially available components. For example, see the reservoir and heater system for controllable delivery of multiple aerosolizable materials of an e-smoking article described in U.S. Patent Application Publication 2014 / 0000638 by Sebastian et al., which is incorporated herein by reference in its entirety. It should be further noted that the reservoir and heater system portion of the cartridge body 200 shown in Figure 1 is optional. In this regard, for example, the cartridge body 200 may not necessarily include, in some examples, the flow tube 210, the control component terminals 206 and / or the electronic control component 208.

[0086] A particular aspect of the present disclosure is shown, for example, in Figure 3. In such an example, the cartridge body 200 may further incorporate a second aerosol generator 400 (where the sprayer 212 is considered the “first aerosol generator”), which is longitudinally positioned on an outer body 216 between the sprayer 212 and the mouthpiece or mouth engagement end 220 of the cartridge body 200. In some embodiments, the second aerosol generator 400 is configured to be porous overall or to allow air to pass through it. In some specific examples, the second aerosol generator 400 may include one or more aerosol generating elements 425, which may consist of at least one or more pellets, beads, other suitable components, or a combination thereof. In some examples, at least one or more pellets, beads, other suitable components, or combinations thereof forming the aerosol generating element 425 may, if necessary, be coaxially surrounded by a cylindrical thermal conductive member (not shown) and / or surrounded by an insulator (e.g., a nonwoven mat or a layer of glass filaments or glass fibers) or other suitable material (not shown), or covered with a jacket.

[0087] The overall configuration of the second aerosol generator 400 in the cartridge body 200 of the aerosol delivery device / system 100 may be considered to be essentially cylindrical in nature. Typical preferred beads or other materials may be produced from a formation incorporating tobacco (e.g., granular tobacco), tobacco and / or tobacco-derived material components (e.g., tobacco extract such as water-soluble tobacco extract or tobacco-derived nicotine containing pharmaceutical-grade nicotine). The beads most preferably incorporate flavor and visible or invisible aerosol-forming materials (e.g., glycerin or other materials that produce visible vapor similar to smoke). That is, the components of the beads are preferably configured to act as substrate components for volatile flavors, vapor-forming materials, water vapor or other liquids, and / or aerosol-forming materials held by the beads. In some embodiments, the aerosol generating element 425 may include, comprise, or be composed of, regardless of whether it is solid, liquid, gelatinous, colloidal, gaseous, or in other forms, and regardless of the following processed materials or combinations, for example, marmerized tobacco beads that change shape and size, bonded (e.g., sintered) bead monoliths, porous monoliths (sponge-like porous structures), single porous structures, honeycomb monoliths or other porous geometric skeletons, single-piece porous materials, extracted tobacco beads, porous material beads that hold tobacco extracts (e.g., calcium carbonate, ceramic, glass, etc.), reconstituted tobacco fragments, puffed tobacco fragments, extruded rods of various materials that hold tobacco flavor (including hollow cylinders and grooved rods), shavings, fibers, flavor-releasing particles, flavor-retaining (and releasing) polymers, granules, cocrystals, capsules, powders and / or microcapsules of various materials that hold tobacco flavor or other substances.

[0088] In some embodiments, the aerosol generating element 425 may be at least partially in the form of a coating or film on the wall or backing of the housing body surrounding the aerosol generating element. For example, a film comprising microencapsulated flavoring agents may be coated on the wall or backing of the housing body.

[0089] Generally, as used herein, the terms “pellets” and “beads” mean beads, pellets, or small discontinuous units or fragments that may include, for example (in addition to those disclosed herein) carbon flakes, extruded carbon flakes cut into pellets, ceramic beads, marmerized tobacco flakes, polymer beads, glass beads, or combinations thereof. For example, granules, pellets, or beads may be generally cylindrical, extruded spherical, or compressed granules, pellets, or beads consisting of a wet mixture or slurry of ground tobacco flakes, a filler (e.g., granular calcium carbonate), a flavoring, a visible aerosol-forming material, and a binder (e.g., carboxymethylcellulose), which are formed, cut or stretched to a desired size and shape, and then dried to retain a desired composition. However, such “pellets” or “beads” may include any preferred composition or combination of composition that satisfies the preferred embodiments disclosed herein. For example, some or all of the beads or pellets may include heat-sensitive spherical capsules that, when exposed to heat, burst or decompose to release glycerin, propylene glycol, water, physiological saline, tobacco flavor and / or nicotine or other substances or additives, contained within the aerosol-generating element. The beads may also contain ceramic, absorbent clay, silica, or absorbent carbon to hold or release the aerosol-forming material. Furthermore, in some embodiments, the beads / pellets may contain a heat-conductive material such as, for example, thermally conductive graphite, thermally conductive ceramic, metal, metal or other suitable material impregnated with suitable aerosol-generating substances such as tobacco, glycerin, and flavor cast into flakes, or a suitable cast sheet material appropriately formed into the desired beads / pellets.

[0090] In a particular example, the beads / pellets (particles) may consist of about 15% to 60% by weight of finely ground tobacco particles (e.g., Oriental Blend, Burley and Yellow Tobacco, essentially all Oriental Tobacco, essentially all Burley Tobacco, or essentially all Yellow Tobacco), about 15% to 60% by weight of finely ground calcium carbonate particles (or finely ground clay or ceramic particles), about 10% to about 50% by weight of glycerol (and a small amount of optional flavoring), about 0.25% to about 15% by weight of a binder (preferably carboxymethylcellulose, guar gum, potassium or ammonium alginate), and about 15% to 50% by weight of water. In other examples, the beads / pellets (particles) may consist of about 30 wt% finely ground tobacco particles (e.g., Oriental Blend, Burley and Yellow tobacco, essentially all Oriental tobacco, essentially all Burley tobacco, or essentially all Yellow tobacco), about 30 wt% finely ground calcium carbonate particles (or finely ground clay or ceramic particles), about 15 wt% glycerol (and a small amount of optional flavoring), about 1 wt% binder (preferably carboxymethylcellulose, guar gum, potassium or ammonium alginate), and about 25 wt% water. In such examples, the particles may be compressed to retain the glycerol, and the compression may form a porous matrix that facilitates the movement of aerosol-forming elements and promotes efficient aerosol formation. The methods by which the aerosol-forming material comes into contact with the substrate are diverse. The aerosol-forming material may be added to the molding material, incorporated into the processing material during the manufacture of those materials, or inherent in the material. The aerosol-forming material, such as glycerin, may be dissolved or dispersed in an aqueous liquid, another suitable solvent, or liquid carrier, or sprayed onto a substrate material. See, for example, Nestor et al., U.S. Patent Application Publication 2005 / 0066986 and Conner et al., 2012 / 0067360, incorporated herein by reference.Calcium carbonate or other inorganic fillers may promote the formation of numerous pores in the particles and, in some examples, may function to absorb heat that can limit or prevent the burning of aerosol-generating elements and the promotion and encouragement of aerosol formation. See also, for example, U.S. Patent Application Publication No. 5,105,831 by Banerjee et al., U.S. Patent Application Publication No. 2004 / 0173229 by Crooks et al., No. 2011 / 0271971 by Conner et al., and No. 2012 / 0042885 by Stone et al., which are incorporated herein by reference.

[0091] In some embodiments, the beads / pellets are fragments of an extruded material comprising granular material that serves as a substrate for flavorings and / or aerosol-forming materials, such as tobacco (e.g., ground tobacco material) or filler material (e.g., rice flour or other grain-based material, and / or calcium carbonate), one or more binders (e.g., carboxymethylcellulose), one or more flavorings (e.g., menthol), and one or more aerosol-forming materials (e.g., glycerin). Optionally, the beads / pellets may also contain one or more organic acids (e.g., levulinic acid or lactic acid) and / or one or more sweeteners (sugar or sugar substitutes). The materials described above may be mixed together, extruded, and fragmented into pieces of desired size. Optionally, the mixed materials may be marmelized.

[0092] In one embodiment, the aerosol-generating elements 425, such as beads or pellets, may be smoked to impart a smoky flavor or aroma. For example, beads or pellets may be prepared and then exposed to smoke from a combustible material such as wood (e.g., hickory, maple, oak, aply, cherry, or mesquite). The beads or pellets may be smoked for a sufficient time to impart the desired smoky flavor or aroma, an exemplary time being between 5 and 45 minutes. The method of bringing the beads or pellets into contact with the smoke is diverse and, in one example, involves heating wood shavings in a container until smoke is produced (e.g., heating the wood shavings to about 350-400 degrees Fahrenheit), and arranging the beads or pellets to be processed in a closed environment with smoke generated by the wood shavings.

[0093] The components of the aerosol precursor composition of the first aerosol generator and the components of the aerosol precursor composition of the second aerosol generator are advantageously selected to complement each other in order to produce a desired sensory experience. For example, in some embodiments, the nicotine content of the aerosol precursor composition and the aerosol generating element is selected such that the aerosol precursor composition and the aerosol generating element can retain nicotine or nicotine components, or can be considered substantially or completely free of nicotine or nicotine components. In other words, all nicotine content may be in the aerosol generating element, all nicotine content may be in the aerosol precursor composition, or both components may contain nicotine in some form.

[0094] In some embodiments, if the aerosol-generating element 425 includes, for example, beads, pellet casts, or extrusions from various types of materials (i.e., graphite beads containing tobacco extract and glycerin), the beads / pellets may be rolled, for example, between adjacent roller elements to flatten the shape of each bead / pellet while "moist" or before drying. In some examples, the various types of materials described above may be extruded in the form of fibrous strands, and the strands may be assembled for use in the second aerosol-generating device 400 to form cylindrical rods or other suitable shapes of material. Once dried, the flattened beads / pellets may be cut or processed to form, for example, strands, flakes, or other filler configurations including flat, non-rotating or obstructive flat portions. Any random configuration resulting from the cutting process may be sufficient. In such an example, flattened and cut beads / pellets may be included in the aerosol-generating element 425, and their irregular or random configuration may, for example, facilitate multiple intermediate spaces that penetrate the aerosol-generating element 425, and these intermediate spaces may facilitate heat transfer with the individual substances in the aerosol-generating element 425. That is, heating of the air in the intermediate spaces within the second aerosol generator 400 exposes more of the aerosol-generating element 425 to heat from the heating element 240, resulting in enhanced or improved heating of the aerosol-generating element 425. In other examples, the heat generated by the heating element 240 / atomizer 212 and the first aerosol (i.e., a combination thereof) are induced through a porous matrix formed by the aerosol generating element 425, through which heated vapor passes and heats the constituent aerosol generating element 425, which in turn facilitates the elution (i.e., extraction of liquid, fluid, or particles, steam distillation, etc.) of reinforcing substances (i.e., flavoring agents or other additives) from the aerosol generating element to the first aerosol, or promotes reinforcing substances that are associated with the first aerosol, imparted to the first aerosol, react with the first aerosol, or interact with the first aerosol.The interaction between the reinforcing material and the first aerosol may, for example, facilitate a reaction that alters or modifies the first aerosol, mixes the reinforcing material with the first aerosol to form a reinforcing aerosol or aerosol mixture, or generates a different aerosol. In such an example, the increased intermediate space within the aerosol generating element 425 may facilitate this interaction process via the second aerosol generating device 400.

[0095] In some embodiments, the beads / pellets may consist of tobacco material cast onto flake / laminated paper. More specifically, the tobacco material may include, for example, a slurry comprising reconstituted tobacco, glycerin, and a binder material. Such tobacco materials are disclosed, for example, in U.S. Patent Application No. 5,101,839 by Jakob et al. and U.S. Patent Application No. 2010 / 0186757 by Crooks et al., incorporated herein by reference. In addition, the slurry may be incorporated into granular inorganic material (i.e., calcium carbonate). For example, as disclosed in U.S. Patent No. 8,678,013 by Crooks et al. and U.S. Patent No. 7,647,932 by Cantrell et al., also incorporated herein by reference, the slurry is cast onto paper elements of flake laminated paper, and the assembled cast sheet product is dried, for example, by applying heat (i.e., heated air, high-frequency drying, etc.). The paper element may have, for example, certain porosity and texture to facilitate adhesion and interaction with the slurry, for example, on direct contact between the slurry and the flake. However, the exemplary embodiments herein do not prevent the tobacco material from being cast onto a metal flake or other suitable thin film thermal conductor. Once such a laminate is cast, the dried cast sheet (i.e., flake / paper / tobacco material) may be cut, shredded, or separated into a plurality of cast sheet sub-elements, each preferably comprising a portion of tobacco material (i.e., a substrate) that closely interacts with a portion of the paper element, and the portion of the paper element adheres to a portion of the flake element of the flake laminate paper. The plurality of cast sheet sub-elements may be included in an aerosol generating element 425 that forms a second aerosol generating apparatus 400.

[0096] In some environments, the peer may have cast sheet elements included in the aerosol generating element 425 cooperate to facilitate improved heat transfer to the tobacco material forming parts of those cast sheet elements, or to adjacent elements. More specifically, in some examples, heat transfer from the heating element 240 to the tobacco material included in the aerosol generating element 425 may be restricted beyond any direct interface between them, and thermal conductive passages may form an additional mechanism for conducting heat from the heating element 240 to heat the aerosol generating element 425 and any external elements included in the aerosol generating element in contact with it. In embodiments including cast sheet elements in the aerosol generating element 425, thermal conductive portions of the thin elements associated with the cast sheet elements may form, for example, a plurality of additional thermal conductive passages. That is, the cast sheet elements used as all or part of the aerosol generating element 425 may provide additional thermally conductive elements scattered throughout the aerosol generating element 425 in the second aerosol generating apparatus 400, thereby enhancing or improving heat transfer to and between the aerosol generating elements. To achieve such an embodiment, it may be even more advantageous to cut or process the substrate material mounted on the cast tobacco sheet substrate material that forms the substrate incorporated into the type of tobacco marketed by RJ Reynolds Tobacco Company under the trade name "Eclipse," as disclosed in U.S. Patent Publication No. 5,469,871, for example, by Barnes et al.

[0097] The pellets or other elements may have a smooth, regular external shape (e.g., spherical, cylindrical, oval, etc.) and / or an irregular external shape (e.g., cut fragments, flakes, etc.). The aerosol generating element 425 may consist of a generally cylindrical shape, added discontinuously or sequentially within the second aerosol generating device 400, and in some examples, it may consist of about 800 to 1200 generally spherical beads, each with an average or nominal diameter of about 0.05 mm to 4 mm (e.g., about 1 cubic millimeter in one example), and the beads / pellets have a cumulative weight of about 450 mg to 750 mg (e.g., around 25% above or below 600 mg in one example).

[0098] In one preparation method, substantially spherical beads or pellets of aerosol-generating elements are formed by a first mixing of the desired components, followed by extrusion of the components to form an extruded product. The extruded product is then processed into a spheronizer (e.g., spheronizers available from Caleva Process Solutions Ltd or LCI Corporation) to produce spherical bodies of various sizes that can be processed by a series of screens to provide a desired range of sizes, such as those described above.

[0099] The aerosol-generating elements may be selected to have a relatively uniform average diameter, or the size range of the aerosol-generating elements may be included in the second aerosol generator 400. When different size ranges are used in the same device, elements of various sizes may be arranged in gradients or layers within the second aerosol generator 400, or elements of various sizes may be randomly mixed within the aerosol generator 400. Although not tied to any particular operating theory, using aerosol-generating elements of different sizes in the same aerosol generator 400 can favorably change the pressure drop within the device and / or provide favorable functional properties based on the different evaporation rates provided by the elements of different sizes.

[0100] It is preferable that a sufficient number of beads are inserted into the second aerosol generator 400, providing at least about 95% of the maximum filling volume with beads and / or other suitable elements. It is advantageous that there are no large cavities within the aerosol generator 400 that allow air to flow through the aerosol generator in order to substantially avoid interaction with the aerosol generating element 425.

[0101] In some examples, multiple shapes of aerosol-generating elements 425 may be selected (for example, aerosol-generating elements having different components), and each selected shape of aerosol-generating element may subsequently be placed in the aerosol generator 400. In other examples, the selected shapes of aerosol-generating elements may be combined to produce a mixture of aerosol-generating elements before being placed in the second aerosol generator 400, after which the mixture may be placed in the second aerosol generator 400.

[0102] The sprayer or first aerosol generator 212 and the second aerosol generator 400 may be physically separated from each other and / or may contain discontinuous units or divisions within the cartridge body 200. In some examples, as shown, these divisions may be positioned / arranged such that the downstream end of the sprayer or first aerosol generator 212 (towards the mouthpiece or mouth engagement end 220 of the cartridge body 200) is adjacent to the upstream end of the second aerosol generator 400 (i.e., the back of the aerosol generating element 425). That is, the sprayer or first aerosol generator 212 and the second aerosol generating division 400 may be adjacent to each other in some examples and aligned axially in a continuous end-to-end relationship. For example, in some configurations, the aerosol generating element 425 of the second aerosol generating device 400 may be physically discontinuous and located downstream from the sprayer or the first aerosol generating device 212, but it may be desirable for the aerosol generating element 425 of the second aerosol generating device 400 to be in physical contact with the heating element 240 at the downstream end of the sprayer or the first aerosol generating device 212. Alternatively, the respective ends or components 240, 425 of these sections 212, 400 may be slightly spaced apart from each other so as not to be in physical contact with each other (i.e., to prevent burning). Competitors will understand that in some configurations, the second aerosol generating device 400 includes one or more sections or parts of the aerosol generating element 425.

[0103] In some examples, additional sections, spacer elements, or separators (hereinafter referred to as “first separators”), or elements acting as spacers or screens (see, for example, component 450 in Figure 3) may be positioned generally perpendicular to the longitudinal axis of the cartridge body 200, with the first separator 450 physically separating the two components 212, 400 while, in some examples, maintaining a thermally conductive relationship between them. The first separator 450 may be non-thermally conductive in some examples and non-conductive in others. That is, the first separator 450 may be thermally conductive and / or configured to conduct heat from the heating element 240 of the atomizer / first aerosol generating element 212 to the second aerosol generating device 400, but not necessarily so, and the aerosol generating element 425 may be highly responsive to heat and / or form a second aerosol in association with the first aerosol. Furthermore, in some examples, the first separation element 450 may be configured to be gas permeable or to allow airflow through it, so that the first aerosol generated by the sprayer / first aerosol generator 400 can travel downstream through the first separation element 450. Alternatively, the first separation element 450 may be configured / positioned to hold the aerosol generating element 425 in the second aerosol generator 400 and separate it from the sprayer / first aerosol generator 212. In that example, the first separation element 450 may also be configured as a spacer (i.e., extending longitudinally along the cartridge body 200 to define its thickness) that separates the aerosol generating element 425 from the heating element 240 of the sprayer / first aerosol generator 212, for example, to prevent the aerosol generating element (i.e., beads) 425 from being burnt or ignited by the heat from the heating element 240. In some examples, the first isolation element 450 may be configured as an insulator (i.e., non-conductive) to prevent the heating element 240 from short-circuiting in the event of contact with the heating element 240.

[0104] Typically, the first separation element 450 is generally cylindrical or disc-shaped, has an integrated structure, and is air-permeable to allow the passage of permeating aspirated air. The first separation element 450 may also be intrinsically thermally conductive, so that the heat generated by the heating element 240 can be quickly transferred to the second aerosol generator 400. The length (thickness) of the first separation element 450 is variable, typically ranging from less than about 1 mm to about 10 mm. In some examples, the relative longitudinal arrangement of the first separation element 450 within the outer body 216 separates the interface between the aerosol generator element 425 and the first separation element 450 from the heating element 240 by about 1 mm to about 20 mm (i.e., 7 mm in one example). Typically, the first separation element 450 consists of a heat-resistant material such as porous ceramic, porous graphite material, metal (i.e., stainless steel, brass, copper, etc.), mesh or screen, or high-temperature heat-resistant plastic. In some examples, the first separation element 450 may include longitudinally extending air channels that are formed, drilled, molded, extruded, printed (i.e., 3D printed elements using a 3D printer), or formed on a spacer element during manufacturing, for example, during design / manufacturing. If desired, the first separation element 450 may incorporate a catalytic material, such as a material incorporating cerium or copper ions or oxides, and / or salts of cerium and copper ions. See, for example, U.S. Patent Publications 8,469,035 and 8,617,263 by Benerjee et al., and U.S. Patent Application Publication 2007 / 0215168 by Benerjee et al., incorporated herein by reference.

[0105] In examples where the aerosol-generating element 425 may be surrounded by an insulating layer, a layer of thermally conductive material (e.g., a layer or strip of metal flakes) may be provided between them (not shown). That is, a typical aerosol-generating element 425 may include a number of pellets and / or other suitable components, which may be surrounded along its longitudinal direction by a layer of strips of metal flakes. Typical metal flakes are, for example, aluminum flakes with a thickness of about 0.01 mm to 0.05 mm. The metal flakes preferably extend along the entire length of the outer coaxial surface of the aerosol-generating element 425, and it is also preferable that the metal flakes extend beyond the first separation element 450 (i.e., at least partially overlap). The thermally conductive material may be provided by means other than using metal flakes. For example, the layer of metal flakes may be replaced by a metal mesh or metal screen. Alternatively, the metal flakes may be replaced by a thermally conductive fabric such as a layer or sheet of graphite fibers or thermally conductive ceramic fibers. Alternatively, the thermally conductive material may be provided by coating it with an ink or paint that incorporates metal particles, graphite fibers, or thermally conductive ceramic materials, or by applying a thermally conductive ink.

[0106] Figure 7 shows an example of a further embodiment of the second aerosol generator 400, which is located in an external body or a tubular member 216 (downstream of the first aerosol generator 212, not shown). As shown, the aerosol generating element 425 is located between the separation elements 450 and 475, thereby holding the aerosol generating element 425 in place and allowing airflow to pass through it. As described above, the separation elements 450 and 475 may be porous elements (e.g., a mesh screen or a perforated metal plate) with hole sizes selected to hold the aerosol generating element 425 in the second aerosol generator 400.

[0107] As shown in the figure, the second aerosol generator 400 may further include another aerosol generating element housing 460 in the shape of a cylindrical housing, for example, having an open end facing a mouthpiece 220, the mouthpiece 220 may engage with the open end of the cylindrical housing and be fixed thereto by press-fit engagement or other known means, as shown. The housing 460 may include an end 470 facing the mouthpiece 220, and the mouthpiece 220 may be perforated to allow airflow to pass through it, as shown. The housing 460 may be made of any suitable material, including metal (e.g., stainless steel) or plastic. The separation elements 450 and 475 may be press-fit engaged or engaged with the housing 460, and the separation element 475 adjacent to the mouthpiece 220 may optionally be fixed to the mouthpiece. In some embodiments, the separation elements 450 and 475 are incorporated into the housing 460 during a molding process that forms the housing. The design shown in Figure 7 is particularly suitable for embodiments of the present invention, in which the second aerosol generator 400 is permanently fixed to the cartridge body 200 rather than being detachable or disposable from the rest of the cartridge body 200.

[0108] Alternatively, in an embodiment in which the second aerosol generator 400 is detachably attached to the cartridge body 200 as a separate unit, the design of Figure 8 is advantageous. As shown, in the embodiment of Figure 8, the second aerosol generator 400 is formed as a separate unit comprising a separate housing body 520 and is attached to the first connector 540 (e.g., by crimping or by other means). The housing 520 and the first connector 540 together form a cavity for the aerosol generating element 425. As in the embodiment of Figure 7, the aerosol generating element 425 is positioned between the separation elements 450 and 475, thereby holding the aerosol generating element 425 in place and allowing airflow to pass through it. Similar to the embodiment of Figure 7, the separation elements 450 and 475 may be press-fit engaged or engaged with the surrounding portions of the first connector 540 or the housing body 520, respectively, and incorporated into these surrounding portions during molding. The downstream separation element 475 is also optionally fixed to the mouthpiece 220.

[0109] The first connector 540 of the second aerosol generator 400 is adapted to engage with a second connector 560, which is fixed (e.g., via press-fit engagement or other means) to an external body or tubular member 216 housing the first aerosol generator 212 (not shown). The second connector 560 has an end facing the first connector 540, which allows the user to detachably secure the second aerosol generator 400 to the cartridge body 200 via screw engagement or other coupling means. As shown, the second connector 560 is porous, allowing airflow from the first aerosol generator 212 to flow into the second aerosol generator 400. The second aerosol generator 400 in this embodiment engages cooperatively with the mouthpiece 220 in a manner similar to that shown in Figure 7.

[0110] In some embodiments, other spacer elements, or other separation elements (hereinafter referred to as “second separation elements”), which act as spacers or screens (see, for example, component 475 in Figure 3), may be positioned generally perpendicular to the longitudinal axis of the cartridge body 200, and the second separation element 475 may physically separate the second aerosol generator 400 from the mouthpiece or mouth engagement end 220 of the cartridge body 200. That is, the second separation element 475 may, but is not necessarily, be thermally conductive and / or configured to conduct heat from the second aerosol generator 400 through the mouthpiece or mouth engagement end 220 of the cartridge body 200. However, the second separation element 475 may be configured to be gas permeable or allow airflow to pass through it, so that the first aerosol generated by the sprayer / first aerosol generator 212 and / or the second aerosol generated by the second aerosol generator 400 can travel downstream through the second separation element 475 and through the mouthpiece or mouth engagement end 220 of the cartridge body 200. Thus, the second separation element 475 may also be configured and / or positioned to maintain the aerosol generating element 425 in the second aerosol generator 400 without any aerosol generating element passing through the mouthpiece or mouth engagement end 220 of the cartridge body 200 being lost.

[0111] In some embodiments, instead of the discontinuous first and second separation elements 450 and 475 implemented in addition to the aerosol generating element 425, the second aerosol generating device 400 may comprise a cartridge 500 (see, for example, Figure 4) having an elongated tubular body 525 and opposing end members 550 and 575, each of which may be thermally conductive and air permeable, in the same manner as the first and second separation elements 450 and 475. Thus, the elongated tubular body 525 may be further configured to receive the aerosol generating element 425 and to cooperate with the opposing end members 550 and 575 to hold the aerosol generating element 425 within the tubular body. Therefore, the assembled cartridge 500 may be configured to be received as a unit (forming the second aerosol generating device 400) by the outer body of the cartridge body 200, i.e., the tubular member 216.

[0112] Figure 9 shows an embodiment of the present invention in which a housing body 520 accommodates a plurality of stackable containers 580a, 580b, 580c, each container containing an aerosol-generating element 425. Each container, for example 580a, may contain a different aerosol-generating element 425 that provides a different sensory experience. Thus, to vary the sensory experience of the aerosol delivery system 100, the user can stack multiple containers of different types in any desired order. Each individual container 580a, 580b, 580c may have a similar structure, such as the general structure shown in Figure 4, where the aerosol-generating element 425 is housed in a container having porous walls that allow a gas flow to pass through it. The number of stackable containers used is variable and is not limited to the three-container embodiment shown. An exemplary range of the total number of stackable containers is from two to about eight (e.g., two, three, four, five, six, seven, or eight containers arranged in a stacked configuration).

[0113] Figure 10 shows an embodiment in which a stackable container 580a, as illustrated in Figure 9, has an internal wall that divides the internal compartment into multiple wedge-shaped compartments so that different aerosol-generating elements 425 (e.g., 425a, 425b, 425c, and 425d) can be placed in separate compartments within the same container. The cross-sectional shape of each subdivided compartment does not have to be wedge-shaped. Additional and non-limiting examples of compartment shapes include concentric, triangular, or quadrilateral compartments. The number and size of the subdivided compartments are variable and are not limited to the four-compartment embodiment shown. The exemplary range of the total number of compartments is from two to about six (e.g., two, three, four, five, or six compartments). The use of an internal wall to divide the compartment into multiple compartments accommodating the aerosol-generating elements 425 is not limited to the embodiment of the stackable container in Figure 9. For example, the single compartment described in Figure 8 may also be subdivided in this manner.

[0114] During use, the mouthpiece or mouth engagement end 220 of the cartridge body 200 of the aerosol delivery system 100 is inserted into the user's mouth. The sprayer / first aerosol generator 212 is operated, for example, by the user's suction (e.g., suction pull) of the mouthpiece or mouth engagement end 220 of the cartridge body 200. The heating element 240 and the liquid transport element 238 are configured to be in a heat exchange relationship. That is, the heat generated by the heating element 240 acts to heat the aerosol precursor composition transported by the liquid transport element 238 to generate the first aerosol. The heat generated by the heating element 240 and the first aerosol are drawn into and through the second aerosol generator 400 (i.e., through the aerosol generating element 425) toward the inhalation port defined by the mouthpiece or mouth engagement end 220. In some examples, heat from the heating element 240 may interact with the aerosol generating element 425 to generate a second aerosol. The second aerosol may interact with or mix with the first aerosol to form a third aerosol, which is delivered to the user through the mouthpiece 220 in response to inhalation applied by the user. In some examples, the heat and / or interaction between the first aerosol and the aerosol generating element 425 may result in a reinforcing substance being applied to the first aerosol to generate a reinforced aerosol. For example, a drug adsorbed on the aerosol generating element 425 may react with the first aerosol and / or heat, or be desorbed from the aerosol generating element 425 by the first aerosol and / or heat, and combine with the first aerosol to form a reinforced aerosol. In yet another example, the aerosol generating element 425 may be configured such that its interaction with the first aerosol draws heat away from the first aerosol (i.e., cooling the first aerosol). When properly implemented by the user, at least a first aerosol is generated by the sprayer 212 and affected by the second aerosol generator 400, and is inhaled into the user's mouth.

[0115] The components in the second aerosol generator 400 and / or aerosol generating element 425 are variable. Generally, the second aerosol generator 400 and / or aerosol generating element 425 may incorporate components that evaporate, aerosolize, or are entrained in the air inhaled through the aerosol delivery system 100 during use. Most preferably, these components provide sensory and sensory effects such as aroma, flavor, mouthfeel, and visible aerosol sensation, either by themselves or in cooperation with the first aerosol produced by the first aerosol generator 212. Examples of components of the first and / or second aerosol generators 212, 400 inhaled into the user's mouth during inhalation include water (e.g., as water vapor), visible or invisible aerosol-forming materials (e.g., glycerin), various volatile flavors (e.g., vanillin and menthol), and volatile components of tobacco (e.g., nicotine).

[0116] Preferred aerosol-forming materials generate aerosols (visible or invisible) by applying sufficient heat to them or through the action of an aerosol-forming state using components of an aerosol delivery system. Preferred aerosol-forming materials generate visible aerosols, which may be considered “smoky.” Preferred aerosol-forming materials are cost-simpler than the chemical properties of smoke produced by burning tobacco. Preferred visible aerosol-forming materials are polyols, and exemplary preferred aerosol-forming materials include glycerin, propylene glycol, and mixtures thereof. If desired, the aerosol-forming material may be combined with other liquid materials such as water. For example, the aerosol-forming material may incorporate a mixture of glycerin and water, or a mixture of propylene glycol and water. See, for example, Crooks et al., U.S. Patent No. 8,678,013, incorporated herein by reference, for various aerosol-forming materials.

[0117] The aerosol-forming material is held or supported by a substrate material to retain the aerosol material within a desired area of ​​the smoking article. Exemplary formations incorporating exemplary substrate materials and aerosol-forming materials include those from Sensabaugh (US No. 4,793,365), White (US No. 4,893,639), Clearman (US No. 5,099,861), Jakob (US No. 5,101,839), Gentry (US No. 5,105,836), Brinkley (US No. 5,159,942), Clearman (US No. 5,203,335), Arzonico (US No. 5,271,419), Lekwauwa (US No. 5,327,917), and Casey. The following are described in U.S. Patent Publication No. 5,396,911 by III, etc., U.S. Patent Publication No. 5,533,530 by Young, etc., U.S. Patent Publication No. 5,588,446 by Clearman, U.S. Patent Publication No. 5,598,868 by Jakob, etc., U.S. Patent Publication No. 5,715,844 by Young, etc., and U.S. Patent Publication No. 2005 / 0066986 by Nestor, etc., which are incorporated herein by reference. See also Chemical and Biological Studies on New Cigarette Prototype that Heat instead of Burn Tobacco, RJ Reynolds Tobacco Company Monograph (1988). Exemplary substrate materials have been incorporated into commercially available cigarettes under the trade names "Premier" and "Eclipse" by RJ Reynolds Tobacco Company.

[0118] In some examples, the aerosol delivery system described with reference to Figure 1 may be used in much the same manner as a commercially available e-cigarette. As a result, when smoked, a preferred aerosol delivery system 100 of the type disclosed herein can produce a visible mainstream aerosol, which is mainly derived from the volatile components of the first and second aerosol generators 212, 400, and which in many respects resembles the mainstream tobacco smoke of a traditional type of cigarette burning tobacco filler.

[0119] In other examples, substantially the entire cartridge body 200 may be formed from one or more carbon materials (see, e.g., Figure 5), which can offer advantages over other cartridge body configurations disclosed herein in terms of biodegradability and the absence of wires. In this regard, the heating element may include carbon foam, the reservoir may include carbonized fabric, and graphite may be employed to form electrical connections with the battery and controller. Examples of carbon-based cartridge bodies are described in U.S. Patent Application Publication 2015 / 0059780 by Davis et al. or 2013 / 0255702 by Griffith et al., which are incorporated herein by reference in their entirety. In some examples, the incorporation of a second aerosol generator disclosed herein may also be applied to such carbon-based cartridge bodies. For example, as shown in Figures 6A and 6B, a portion 625 of a cartridge element 600 positioned in the mouthpiece direction of the cartridge body (see, e.g., Figure 6A) may be configured or modified to receive one or more aerosol generating elements 425 of the type disclosed herein (see, e.g., Figure 6B). Alternatively, a pre-assembled cartridge containing such aerosol-generating element 425 may be implemented, or, as disclosed herein, the cartridge element 600 and / or an external body receiving the cartridge element 600 may be configured to receive first and second separation elements having the aerosol-generating element between them.

[0120] A person skilled in the art, having the merits of the teachings presented in the above description and the accompanying drawings, will likely envision many modifications and other embodiments of the disclosure to which this disclosure relates. For example, such a person will understand that embodiments not expressly described herein are practiced within the scope of the claims, and that features described herein for other embodiments may be combined with each other and / or with known or future-developed technologies. Accordingly, it should be understood that this disclosure is not limited to the specific embodiments disclosed herein, and that equivalents, modifications and other embodiments are intended to be included within the scope of the appended claims.

Claims

1. Aerosol delivery system, A control unit comprising a first elongated tubular member having opposing ends and a power supply disposed therein, A cartridge body comprising a second tubular member having opposing first and second ends, wherein the first end engages with one of the opposing ends of the control body, and the cartridge body further comprises a first aerosol generating device disposed within the second tubular member, configured to operably engage the power supply through engagement between one of the opposing ends of the control body and the first end of the cartridge body, wherein the second end of the cartridge body faces the mouth engagement end of the aerosol delivery system, A second aerosol generating device is disposed between the first aerosol generating device and the mouth engagement end of the aerosol delivery system, and is detachably engaged with the cartridge body or housed in the second tubular member of the cartridge body, Equipped with, The second aerosol generating apparatus further includes a plurality of bead-shaped or pellet-shaped aerosol generating elements, An aerosol delivery system in which each bead or pellet is in the form of an extruded material comprising granular material selected from tobacco material and filler, at least one aerosol-forming material, and at least one binder.

2. The aerosol product according to claim 1, further comprising a first separation element disposed within a second tubular member between the first aerosol generating apparatus and the second aerosol generating apparatus, wherein the first separation element is either thermally conductive or gas permeable.

3. The aerosol delivery system according to claim 2, wherein a first separation element extends along a longitudinal axis between opposing ends to define a thickness, and the thickness of the first separation element is configured to separate the second aerosol generator from the heating element of the first aerosol generator.

4. The aerosol delivery system according to claim 1, further comprising a second separation element between the second aerosol generating device and the mouth engagement end, wherein the second separation element is either thermally conductive or gas permeable.

5. The aerosol delivery system according to claim 1, wherein the second aerosol generating device comprises a cartridge having an elongated tubular body and opposing end members, each of the end members being either thermally conductive or gas permeable, the elongated tubular body is further configured to receive a plurality of aerosol generating elements and to house the plurality of aerosol generating elements therein in cooperation with the opposing end members, and the cartridge is configured to be received by the second tubular body.

6. The aerosol delivery system according to claim 1, wherein the first aerosol generating device comprises a liquid container disposed within the second tubular member and is configured to receive an aerosol precursor substance used by the first aerosol generating device to generate the first aerosol.

7. The aerosol delivery system according to claim 6, wherein the aerosol precursor substance is any of glycerin, propylene glycol, water, physiological saline, nicotine, an organic acid, or a combination thereof.

8. The aerosol delivery system according to claim 1, wherein the first aerosol generating device is configured to provide heat for generating a first aerosol, and the second aerosol generating device includes at least one aerosol generating element, the at least one aerosol generating element being arranged to interact with the first aerosol, which is drawn through the aerosol generating element to the mouth engagement end in response to the heat and suction applied to the mouth engagement end.

9. The aerosol delivery system according to claim 1, wherein the aerosol-generating element further comprises one or more of granular tobacco, tobacco extract, and nicotine, and the nicotine is in free basic form, salt form, complex, or solvated compound.

10. The aerosol delivery system according to claim 1, wherein the aerosol generating element further comprises one or more flavoring agents.

11. The aerosol delivery system according to claim 1, wherein the second aerosol generating device is housed within the second tubular member of the cartridge body and includes a plurality of bead-shaped or pellet-shaped aerosol generating elements held in place by a first air-permeable separation element positioned within the second tubular member between the first aerosol generating device and the second aerosol generating device, and a second separation element between the second aerosol generating device and the mouth engagement end.

12. The aerosol delivery system according to claim 1, wherein the second aerosol generating device includes a plurality of bead-shaped or pellet-shaped aerosol generating elements that are detachably engaged with the cartridge body and held in place by a first air-permeable separation element between the first aerosol generating device and the second aerosol generating device, and a second separation element between the second aerosol generating device and the mouth engagement end.

13. The aerosol delivery system according to claim 1, wherein the second aerosol generating device comprises an external housing body and a plurality of stackable, gas-permeable containers within the external housing body, each container containing a plurality of aerosol generating elements.

14. The aerosol delivery system according to claim 1, wherein the second aerosol generating device comprises an external housing body and an internal compartment subdivided into a plurality of subcompartments, each subcompartment housing a plurality of aerosol generating elements.

15. The aerosol delivery system according to claim 1, wherein the beads or pellets comprise a substrate material selected from the group consisting of glass beads, fibers, honeycomb structures, porous monoliths, and polymer beads.

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