Smoking products

Abstract

To provide aerosol delivery devices and systems that utilize combustible carbon-based ignition sources or electrically generated heat for production of aerosol.SOLUTION: A smoking article 100 includes: a heat source 102 configured to generate heat upon ignition of the heat source; a first substrate material 106 having an aerosol precursor composition coupled with the first substrate material, and having a first end fixedly engaged with the heat source; and an aerosol delivery component 108 having opposed first and second ends, the first end of the aerosol delivery component being engaged with the second end of the first substrate material. In some aspects, the aerosol delivery component includes: a second substrate material 114 having the aerosol precursor composition coupled with the second substrate material, and disposed about the first end of the aerosol delivery component; and a tobacco material 124 disposed between the second substrate material and a mouthpiece 116.SELECTED DRAWING: Figure 1A

Description

[Technical field]

[0001] The present disclosure relates to aerosol delivery devices and systems, such as smoking articles, and more particularly to aerosol delivery devices and systems that utilize a combustible carbon-based ignition source or electrically generated heat for the generation of an aerosol (e.g., smoking articles for obtaining tobacco and other material components in an inhalable form, commonly referred to as heat-not-burn systems or e-cigarettes). Highly preferred components of such articles are made from or derived from tobacco, or these articles may be characterized as otherwise incorporating tobacco for human consumption, and are capable of vaporizing the tobacco and / or other tobacco-related material components to form an inhalable aerosol for human ingestion. [Background technology]

[0002] Many smoking devices have been proposed over the years as an improvement or replacement for smoking products that require tobacco to be burned for use. Many of these devices are designed to provide the sensation associated with smoking cigarettes, cigars or pipes, but are said to not deliver significant amounts of incomplete combustion products and / or pyrolysis products resulting from tobacco combustion. To this end, many smoking products, flavor generators and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials or attempt to provide the smoking sensation of cigarettes, cigars or pipes without significantly burning tobacco. For example, see the various alternative smoking articles, aerosol delivery devices and heat sources described in the background art described in U.S. Patent No. 7,726,320 to Robinson et al. and U.S. Patent Application Publication No. 2013 / 0255702 to Griffith, Jr. et al. and U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., which are incorporated herein by reference. See also, for example, the various types of smoking articles, aerosol delivery devices, and electrical heating sources referenced by trade names and commercial sources described in U.S. Patent Application Publication No. 2015 / 0220232 to Bless et al., which is incorporated herein by reference. Additional types of smoking articles, aerosol delivery devices, and electrical heating sources referenced by trade names and commercial sources are described in U.S. Patent Application Publication No. 2015 / 0245659 to DePiano et al., which is also incorporated herein by reference in its entirety.

[0003] Certain tobacco products that use electrical energy to generate heat for aerosol formation, particularly so-called e-cigarette products, are commercially available worldwide. Representative products that mimic many of the attributes of a traditional cigarette, cigar or pipe include ACCORD® by Philip Morris Incorporated, ALPHA™, JOYE 510™ and M4™ by InnoVapor LLC, CIRRUS™ and FLING™ by White Cloud Cigarettes, BLU™ by Lorillard Technologies, Inc., COHITA™, COLIBRI™, ELITE CLASSIC™, MAGNUM™, PHANTOM™ and SENSE™ by EPUFFER® International Inc., DUOPRO™, STORM™ and VAPORKING® by Electronic Cigarettes, Inc., EGAR™ by Egar Australia, eGo-C™ and eGo-T™ by Joyetech, ELUSION™ by Elusion UK Ltd, Eonsmoke EONSMOKE(R) by FIN Branding Group, LLC; FIN(TM) by FIN Branding Group, LLC; SMOKE(R) by Green Smoke Inc. USA; GREENARETTE(TM) by Greenarette LLC; HALLIGAN(TM), HENDU(TM), JET(TM), MAXXQ(TM), PINK(TM) and PITBULL(TM) by SMOKE STIK(R); HEATBAR(TM) by Philip Morris International, Inc.; HYDRO IMPERIAL(TM) and LXE(TM) by Crown7; LOGIC(TM) and THE CUBAN(TM) by LOGIC Technology; LUCI(R) by Luciano Smokes Inc.; METRO(R) by Nicotek, LLC; NJOY(R) and ONEJOY(TM) by Sottera, Inc.; NO. by SS Choice LLC.7(TM), PREMIUM ELECTRONIC CIGARETTE(TM) by PremiumEstore LLC, RAPP E-MYSTICK(TM) by Ruyan America,Inc., RED DRAGON(TM) by Red Dragon Products,LLC, RUYAN(R) by Ruyan Group(Holdings)Ltd., SF(R) by Smoker Friendly International,LLC, GREEN SMART SMOKER(R) by The Smart Smoking Electronic Cigarette Company Ltd., SMOKE ASSIST(R) by Coastline Products LLC, SMOKING EVERYWHERE(R) by Smoking Everywhere,Inc., V2CIGS(TM) by VMR Products LLC, VAPOR NINE(TM) by VaporNine LLC, VAPOR4LIFE(R) by Vapor 4 Life,Inc., VEPPO(TM) by E-CigaretteDirect,LLC, RJ Reynolds Vapor These include the VUSE product by Mistic Company, the Mistic Menthol product by Mistic Ecigs, and the Vype product by CN Creative Ltd. Still other electric aerosol delivery devices, particularly those characterized as so-called electronic cigarettes, are marketed under the trade names COOLER VISIONS™, DIRECT E-CIG™, DRAGONFLY™, EMIST™, EVERSMOKE™, GAMUCCI®, HYBRID FLAME™, KNIGHT STICKS™, ROYAL BLUES™, SMOKETIP®, and SOUTH BEACH SMOKE™.

[0004] In some instances, conventional smoking articles such as those referenced above are difficult for consumers to assemble as a result of multiple components that must be disassembled and reassembled upon consumption of the aerosol delivery components provided in the smoking article. In some other instances, some smoking articles, particularly those that use conventional paper wrapping materials, also tend to scorch the paper wrapping material that covers the ignitable fuel source due to the high temperatures achieved by the fuel source in close proximity to the paper wrapping material. This can reduce the enjoyment of the smoking experience for some consumers and can mask or undesirably alter the flavor delivered to the consumer by the aerosol delivery components of the smoking article. In yet another example, conventional smoking articles can generate relatively significant levels of carbon monoxide during use. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] U.S. Patent No. 7,726,320 [Patent Document 2] US Patent Application Publication No. 2013 / 0255702 [Patent Document 3] US Patent Application Publication No. 2014 / 0096781 [Patent Document 4] US Patent Application Publication No. 2015 / 0220232 [Patent Document 5] US Patent Application Publication No. 2015 / 0245659 Summary of the Invention [Problem to be solved by the invention]

[0006] It would therefore be desirable to provide smoking articles that solve the technical problems sometimes associated with conventional smoking articles, including, but not limited to, two-component smoking articles, smoking articles that include a reloadable cartridge enclosed by a thermal casing, and / or battery-powered smoking articles. [Means for solving the problem]

[0007] Disclosed herein is a smoking article. In one embodiment, the smoking article includes a heat source configured to generate heat upon ignition of the heat source, a first substrate having opposing first and second ends, the first end of the first substrate being fixedly engaged with the heat source, the first substrate having an aerosol precursor composition bonded to the first substrate, and an aerosol delivery component having opposing first and second ends, the first end of the aerosol delivery component being engaged with the second end of the first substrate, the aerosol delivery component having an aerosol precursor composition bonded to the aerosol delivery component. The aerosol precursor composition includes a second substrate having a composition and disposed about a first end of the aerosol delivery component, a mouthpiece having a filter material and disposed about the second end of the aerosol delivery component, and a tobacco material disposed between the second substrate and the mouthpiece, wherein the aerosol precursor composition combined with the first and second substrates is configured to generate an aerosol in response to heat generated by an ignited heat source, and the aerosol is drawn through the tobacco material and through the filter material of the mouthpiece in response to drawing applied to the mouthpiece.

[0008] In another aspect, a smoking article comprises an aerosol generation module and a tubular casing, the aerosol generation module comprising a heat source configured to generate heat upon ignition thereof; an aerosol delivery component having opposing first and second ends, the first end engaged with the heat source, the aerosol delivery component comprising tobacco material combined with an aerosol precursor composition and disposed within the tubular member, the aerosol delivery component configured to generate an aerosol in response to heat generated by the heat source; and a mouthpiece engaged to the second end of the aerosol delivery component, the mouthpiece configured to receive the aerosol in response to draw applied to the mouthpiece, the tubular casing constructed from an insulating material, the tubular casing configured to internally receive at least the heat source and the aerosol delivery component of the aerosol generation module in coaxial relationship therewith, the tubular casing configured to thermally regulate conduction of heat generated by the ignited heat source through the tubular casing.

[0009] In a further aspect, a smoking article includes a power source having opposing first and second ends defining an axis extending through the power source; a heat source in communication with the second end of the power source and extending along the axis, the heat source configured to generate heat in response to power received from the power source; a tubular casing having a first end engaged to the second end of the power source and extending axially around the heat source to the second end; a solid tobacco material contained within the tubular casing, the solid tobacco material configured as a cylindrical tube extending around a circumference of the axially extending heat source between the heat source and the tubular casing, the solid tobacco material configured to generate an aerosol in response to heat generated by the heat source; and a mouthpiece defined by the second end of the tubular casing opposite the cylindrical tube of solid tobacco material from the power source, the mouthpiece configured to receive an aerosol from the solid tobacco material in response to draw applied to the mouthpiece.

[0010] Accordingly, the present disclosure includes, but is not limited to, the following embodiments.

[0011] Embodiment 1: A smoking article comprising: a heat source configured to generate heat upon ignition of the heat source; a first substrate having opposing first and second ends, the first end of the first substrate fixedly engaged with the heat source, the first substrate having an aerosol precursor composition associated with the first substrate; and an aerosol delivery component having opposing first and second ends, the first end of the aerosol delivery component engaged with the second end of the first substrate, the aerosol delivery component comprising an aerosol precursor composition associated with the second substrate. a second substrate having a filter material and disposed around a first end of the aerosol delivery component; a mouthpiece having a filter material and disposed around the second end of the aerosol delivery component; and a tobacco material disposed between the second substrate and the mouthpiece, wherein an aerosol precursor composition coupled with the first and second substrates is configured to generate an aerosol in response to heat generated by an ignited heat source, and the aerosol is drawn through the tobacco material and through the filter material of the mouthpiece in response to draw applied to the mouthpiece.

[0012] Embodiment 2: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the aerosol delivery component includes a cylindrical housing defining a cavity configured to receive and retain tobacco material between the second substrate and the mouthpiece.

[0013] Embodiment 3: The smoking article of any preceding embodiment, or any combination of the preceding embodiments, further comprising an outer wrap configured to surround the heat source, a first substrate engaged to the heat source around a first end of the first substrate, and an aerosol delivery component engaged to a second end of the first substrate.

[0014] Embodiment 4: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the outer wrap comprises a lining material disposed adjacent to the heat source, the first substrate and the aerosol delivery component, and the lining material is configured to thermally regulate the conduction of heat generated by the ignited heat source radially outward of the lining material.

[0015] Embodiment 5: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the lining material comprises a material selected from the group consisting of foil, graphene, graphite and aluminium oxide.

[0016] Embodiment 6: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the first substrate and the second substrate comprise cellulose acetate, and the aerosol precursor composition comprises glycerin coated on the cellulose acetate.

[0017] Embodiment 7: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the tobacco material comprises tobacco-containing beads, shredded tobacco, strips of tobacco, pieces of reconstituted tobacco material, or a combination thereof.

[0018] Embodiment 8: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the heat source comprises an extruded monolithic carbonaceous material.

[0019] Embodiment 9: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the extruded monolithic carbonaceous material defines one or more channels extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material.

[0020] Embodiment 10: A smoking article comprising an aerosol generation module and a tubular casing, the aerosol generation module comprising: a heat source configured to generate heat upon ignition of the heat source; an aerosol delivery component having opposing first and second ends, the first end engaged with the heat source, the aerosol delivery component comprising tobacco material combined with an aerosol precursor composition and disposed within the tubular member, the aerosol precursor composition combined with the tobacco material configured to generate an aerosol in response to heat generated by the heat source; and a mouthpiece engaged with the second end of the aerosol delivery component, the mouthpiece configured to receive the aerosol in response to draw applied to the mouthpiece, the tubular casing being constructed from a thermally insulating material, the tubular casing being configured to internally receive at least the heat source and the aerosol delivery component of the aerosol generation module in coaxial relationship therewith, the tubular casing being configured to thermally regulate conduction of heat generated by the ignited heat source through the tubular casing.

[0021] Embodiment 11: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, further comprising a packaging material configured to surround at least the heat source and the aerosol delivery component of the aerosol generation module and engage the heat source with a first end of the aerosol delivery component, and wherein the tubular casing is configured to removably receive at least the heat source and the aerosol delivery component of the aerosol generation module surrounded by the packaging material.

[0022] Embodiment 12: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the mouthpiece of the aerosol generation module is removably engaged with the tubular casing.

[0023] Embodiment 13: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the tubular member of the aerosol delivery component comprises extruded carbon or graphite.

[0024] Embodiment 14: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the aerosol delivery component includes an annular portion extending around the second end of the tubular member and configured to engage the mouthpiece.

[0025] Embodiment 15: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the annular portion is ultrasonically welded or sealed to the mouthpiece or to the second end of the tubular member.

[0026] Embodiment 16: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the annular portion is configured to receive the second end of the tubular member, the mouthpiece being welded or sealed to the annular portion.

[0027] Embodiment 17: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the mouthpiece is configured to receive the annular portion therein, and the annular portion is welded or sealed to the second end of the tubular member.

[0028] Embodiment 18: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein at least one of the annulus and the mouthpiece comprises a biodegradable plastic.

[0029] Embodiment 19: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the mouthpiece comprises a tubular casing configured to receive a filter material therein.

[0030] Embodiment 20: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the tobacco material is coated with an aerosol precursor composition.

[0031] Embodiment 21: The smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the insulating material of the tubular casing comprises a ceramic material, graphite or graphene.

[0032] Embodiment 22: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the tobacco material comprises tobacco-containing beads, shredded tobacco, strips of tobacco, pieces of reconstituted tobacco material, or combinations thereof.

[0033] Embodiment 23: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the aerosol precursor composition comprises glycerin.

[0034] Embodiment 24: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the heat source comprises an extruded monolithic carbonaceous material.

[0035] Embodiment 25: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the extruded monolithic carbonaceous material defines one or more channels extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material.

[0036] Embodiment 26: A smoking article comprising: a power source having opposing first and second ends defining an axis extending through the power source; a heat source in communication with the second end of the power source and extending along the axis, the heat source configured to generate heat in response to power received from the power source; a tubular casing having a first end engaged with the second end of the power source and extending axially around the heat source to the second end; a solid tobacco material contained within the tubular casing, the solid tobacco material configured as a cylindrical tube extending around a circumference of the axially extending heat source between the heat source and the tubular casing, the solid tobacco material configured to generate an aerosol in response to heat generated by the heat source; and a mouthpiece defined by the second end of the tubular casing opposite the cylindrical tube of solid tobacco material from the power source, the mouthpiece configured to receive an aerosol from the solid tobacco material in response to draw applied to the mouthpiece.

[0037] Embodiment 27: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, further comprising a filter material extending at least partially around a periphery of the cylindrical tube of solid tobacco material and around the second end of the tubular casing within the mouthpiece.

[0038] Embodiment 28: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the filter material comprises cellulose acetate.

[0039] Embodiment 29: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the power source comprises a lithium ion battery.

[0040] Embodiment 30: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the heat source is a cylindrical rod electrically connected to a lithium ion battery.

[0041] Embodiment 31: A smoking article of any preceding embodiment, or any combination of preceding embodiments, wherein the power source is housed in a tubular control enclosure having opposing first and second ends, the second end of the tubular control enclosure being engaged with the first end of the tubular casing.

[0042] Embodiment 32: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, further comprising a control unit in communication with the power source, the control unit configured to activate power generated by the power source and direct power to the heat source.

[0043] Embodiment 33: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, further comprising a push button in communication with the control unit, the push button configured to control operation of the power generated by the power source.

[0044] Embodiment 34: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the tubular casing comprises an insulating material.

[0045] Embodiment 35: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the insulating material comprises graphite or graphene.

[0046] Embodiment 36: A smoking article of any preceding embodiment, or any combination of the preceding embodiments, wherein the solid tobacco material comprises tobacco-containing beads, shredded tobacco, strips of tobacco, pieces of reconstituted tobacco material, or a combination thereof.

[0047] These and other features, aspects, and advantages of the present disclosure will become apparent from a reading of the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four, or more features or elements described in this disclosure or recited in any one or more of the claims, regardless of whether such features or elements are explicitly combined or otherwise recited in the description of a particular embodiment or in the claims herein. The present disclosure is intended to be read as a whole such that any separable features or elements of the disclosure, in any of its aspects and embodiments, appear as intended to be combinable, unless the context of the disclosure clearly dictates otherwise.

[0048] Having described the present disclosure in general terms above, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. [Brief description of the drawings]

[0049] [Figure 1A] FIG. 1 shows a perspective view of one embodiment of a smoking article including a heat source and an aerosol delivery component in an exploded configuration according to the present disclosure. [Figure 1B] 1B shows the smoking article of FIG. 1A in an assembled configuration with an outer wrap surrounding the heat source and aerosol delivery components. [Figure 2A]FIG. 2 shows a perspective view of another embodiment of a smoking article according to the present disclosure, including an aerosol generation module having a heat source, an aerosol delivery component and a mouthpiece in an exploded configuration. [Figure 2B] 2B shows the aerosol generation module of FIG. 2A in an assembled configuration with packaging material surrounding at least the heat source and aerosol delivery components of the aerosol generation module. [Figure 2C] 2B shows an exemplary embodiment of a tubular casing for receiving at least the heat source and aerosol delivery components of the aerosol generation module of FIG. 2A. [Figure 2D] 2C shows the smoking article of FIG. 2A in an assembled configuration with the tubular casing of FIG. 2C. [Figure 3A] FIG. 2 shows a perspective view of a further embodiment of a smoking article in an exploded configuration according to the present disclosure, the smoking article including a power source and a heat source having solid tobacco material distributed annularly around the heat source and contained in a tubular casing. [Figure 3B] FIG. 3B shows a detailed view of the tubular casing of FIG. 3A. [Figure 3C] 3B shows the aerosol generation module of FIG. 3A in an assembled configuration. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0050] The present disclosure will now be described in further detail with reference to exemplary embodiments thereof. These exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0051] The present disclosure provides a description of an article that uses electrical energy to heat a material (preferably without significantly burning the material) to form an aerosol and / or an inhalable substance. Most preferably, such an article is small enough to be considered a "handheld" device. In certain highly preferred embodiments, the article is characterized as a smoking article. The term "smoking article" as used herein is intended to mean an article and / or device that provides many of the sensations of smoking a cigarette, cigar, or pipe (e.g., the type of inhalation and exhalation, the type of taste or flavor, the sensory stimulating effect, the physical feel, the type of use, the visual stimuli as provided by a visible aerosol, etc.) without substantially burning any of the components of the article and / or device. The term "smoking article" as used herein does not necessarily mean that, during operation, the article or device produces smoke in the sense of an aerosol resulting from the by-products of tobacco combustion or pyrolysis, but rather, that the article or device produces vapor (including vapor in an aerosol that is considered a visible aerosol that can be considered as described as smoke-like) due to volatilization or vaporization of certain components, elements, etc. of the article and / or device. In highly preferred aspects, articles or devices that can be characterized as smoking articles incorporate tobacco and / or tobacco-derived components.

[0052] The article or device of the present disclosure may also be characterized as being a vapor product, an aerosol delivery article, or a drug delivery article. Thus, such an article or device may be configured to provide one or more substances in an inhalable form or state. For example, the inhalable substance is substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance is in aerosol form (i.e., a suspension of fine solid particles or liquid droplets in a gas). For ease of understanding, the term "aerosol" as used herein is meant to include vapors, gases, and aerosols in any form or type suitable for human inhalation, whether or not visible and whether or not in a form that can be considered as smoke-like.

[0053] Smoking articles of the present disclosure, when in use, are subject to many of the physical actions of an individual when using a conventional smoking article (e.g., a cigarette, cigar, or pipe that is used by igniting it with a flame and then inhaling the burnt and / or combusted tobacco). For example, a user of a smoking article of the present disclosure holds the article as a conventional smoking article, draws on one end of the article to inhale the aerosol produced by the article, and takes a puff for a selected time interval.

[0054] The smoking article of the present disclosure generally includes a number of elements that are provided or housed in some kind of enclosure, such as a housing, an outer wrap or packaging, a casing, a component, a module, a member, etc. The overall design of the enclosure is variable, as is the type or configuration of the enclosure that defines the overall size and shape of the smoking article. In some embodiments, it is desirable for the overall design, size and / or shape of the enclosure to resemble that of a traditional cigarette or cigar. Typically, an enclosure that resembles the shape of a cigarette or cigar includes three or more separable components, members, etc. that are engaged to form the enclosure. For example, such a smoking article includes three separable components, including a mouthpiece component, an aerosol delivery component, and a heat source component, in some embodiments.

[0055] However, according to certain aspects of the present disclosure, it is advantageous to reduce the number of components required for the assembly of such smoking articles. Thus, the number of components of the smoking articles described herein is reduced from those generally known in some examples to simplify the assembly of the smoking article. Thus, in one example (see, for example, Figures 1A and 1B), a two-component smoking article having two components is disclosed herein, in which the aerosol delivery component and the mouthpiece component are combined to form a single component that can be engaged with the heat source component to facilitate assembly. Other simplifications of the assembly of multi-component smoking articles are also contemplated herein.

[0056] A smoking article of the present disclosure includes any combination of elements, including within an enclosure, such as a power source (e.g., an electrical power source), at least one control component (e.g., an actuation mechanism; a configuration for activating, controlling, regulating, and terminating power for heat generation, such as by controlling the flow of current from the power source to other components of the article), a heat source or other heat generating element (e.g., a fuel element configured to be ignited to burn by smoldering and generate heat), an aerosol delivery component (e.g., a substrate combined with an aerosol precursor composition, solid tobacco and / or tobacco-related material, aerosol-generating liquid, etc.), and a mouthpiece component, end region, portion, or tip that allows drawing on the smoking article for aerosol inhalation through the mouthpiece component, end region, portion, or tip (e.g., a defined air flow path through the article such that generated aerosol is directed through the mouthpiece component, end region, portion, or tip in response to drawing applied to the mouthpiece component, end region, portion, or tip). The arrangement and configuration of the elements within the article through the enclosure is variable. In certain embodiments, the aerosol delivery component is disposed between the mouthpiece component and the heat source and / or power source, although other configurations are not excluded. For example, in some embodiments, the power source and / or heat source is disposed between the aerosol delivery component and the mouthpiece component.

[0057] In general, the heat source is positioned sufficiently close to the aerosol delivery component such that the aerosol (and one or more flavoring materials, agents, etc., similarly provided for delivery to the user) formed / volatilized by application of heat from the heat source to the aerosol delivery component is deliverable to the user through the mouthpiece. That is, when the heat source heats the aerosol delivery component, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the above terms mean that references to release, releasing, releases, or released can be restated to include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol, or a mixture thereof. Furthermore, the selection of various smoking article elements is understood in light of commercially available electronic smoking articles, such as the representative products listed in the Background section of this disclosure.

[0058] In various embodiments, the heat source is formed from a material that generates heat in a number of ways. For example, the heat source is formed from a material that has a specific resistance and provides resistive heating when a current is applied across the specific resistance. In another example, the heat source is formed from a combustible material that provides heat when the heat source is ignited. In either case, the heat source can generate heat to aerosolize the aerosol delivery component. The aerosol delivery component includes, for example, extruded structures and / or substrates in solid or liquid form (e.g., beads, shreds, wraps), substrates combined with aerosol precursor compositions, tobacco and / or tobacco-derived materials (i.e., materials directly isolated from tobacco, naturally found in tobacco, or synthetically prepared materials), and the like.

[0059] In some embodiments, the aerosol delivery component comprises a blend of flavorful, aromatic tobacco in cut filler form. In another embodiment, the aerosol delivery component comprises a reconstituted tobacco material as described in U.S. Pat. No. 4,807,809 to Pryor et al., U.S. Pat. No. 4,889,143 to Pryor et al., and U.S. Pat. No. 5,025,814 to Raker, the disclosures of which are incorporated herein by reference in their entirety. Additionally, the reconstituted tobacco material comprises reconstituted tobacco paper for cigarettes of the type described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, RJ Reynolds Tobacco Company Monograph (1988), the contents of which are incorporated herein by reference in their entirety. For example, the reconstituted tobacco material comprises a sheet-like material containing tobacco and / or tobacco-related materials. Thus, in some embodiments, the aerosol delivery component is formed from a wound roll of reconstituted tobacco material. In another embodiment, the aerosol delivery component is formed from shreds, strips, etc. of reconstituted tobacco material.

[0060] According to another aspect, a smoking article according to the present disclosure includes an aerosol delivery component comprising a porous inert material, such as, for example, a ceramic material. In another aspect, the aerosol delivery component comprises a porous inert material that is substantially chemically and / or physically unreactive with tobacco-related materials, such as, for example, tobacco-derived extracts.

[0061] Tobacco for use in the aerosol delivery component may include or be derived from tobaccos such as flue-cured, burley, oriental, Maryland, dark tobacco, dark-fired tobacco, and rustica, as well as other rare or specialty tobaccos, or blends thereof. Various representative tobacco types, processed types, and tobacco blend types are described in U.S. Patent No. 4,836,224 to Lawson et al., U.S. Patent No. 4,924,888 to Perfetti et al., U.S. Patent No. 5,056,537 to Brown et al., U.S. Patent No. 5,159,942 to Brinkley et al., U.S. Patent No. 5,220,930 to Gentry, U.S. Patent No. 5,360,023 to Blakley et al., U.S. Patent No. 5,360,023 to Shafer et al., the disclosures of which are incorporated herein by reference in their entireties. No. 6,701,936 to Dominguez et al., U.S. Pat. No. 6,730,832 to Dominguez et al., U.S. Pat. No. 7,011,096 to Li et al., U.S. Pat. No. 7,017,585 to Li et al., U.S. Pat. No. 7,025,066 to Lawson et al., U.S. Patent Application Publication No. 2004 / 0255965 to Perfetti et al., PCT Publication WO 02 / 37990 to Bereman, and Bombick et al., Fund. Appl. Toxicol., 39, pp. 11-17 (1997).

[0062] According to another aspect of the present disclosure, the aerosol delivery component includes tobacco, tobacco components and / or tobacco-derived materials that have been processed, manufactured, produced and / or processed to incorporate an aerosol precursor composition (e.g., a humectant, e.g., propylene glycol, glycerin, etc.) and / or at least one flavoring agent, as well as a flame retardant (e.g., diammonium phosphate and / or another salt) configured to help prevent ignition, pyrolysis, combustion and / or charring of the aerosol delivery component by a heat source. Various modes and methods for incorporating tobacco into smoking articles, particularly smoking articles designed to intentionally avoid burning substantially any tobacco within the smoking article, are described in U.S. Pat. No. 4,947,874 to Brooks et al., U.S. Pat. No. 7,647,932 to Cantrell et al., U.S. Pat. No. 8,079,371 to Robinson et al., U.S. Pat. No. 7,290,549 to Banerjee et al., and U.S. Patent Application Publication No. 2007 / 0215167 to Crooks et al., the entire disclosures of which are incorporated herein by reference.

[0063] According to one aspect of the present disclosure, the flame retardant / flame retardant materials and additives that can be included in the aerosol delivery component include organophosphorus compounds, borax, hydrated alumina, graphite, potassium tripolyphosphate, dipentaerythritol, pentaerythritol and polyols. Others such as nitrogen phosphonates, monoammonium phosphates, ammonium polyphosphates, ammonium bromide, ammonium borate, ethanolammonium borate, ammonium sulfamate, halogenated organic compounds, thiourea and antimony oxide are also suitable but are not preferred agents. In each aspect of the flame retardant, flame retardant and / or scorch retardant materials used in the aerosol delivery component and / or other components (whether alone or in combination with each other and / or other materials), the desired properties are most preferably provided without undesirable outgassing or melting type behavior.

[0064] According to another aspect of the present disclosure, the aerosol delivery component also incorporates tobacco additives of the type conventionally used in the manufacture of tobacco products. These additives include the type of materials used to enhance the flavor and aroma of tobacco used in the manufacture of cigars, cigarettes, pipes, etc. For example, these additives include various cigarette casing components and / or top dressing components. See, for example, U.S. Patent No. 3,419,015 to Wochnowski, U.S. Patent No. 4,054,145 to Berndt et al., U.S. Patent No. 4,887,619 to Burcham, Jr. et al., U.S. Patent No. 5,022,416 to Watson, U.S. Patent No. 5,103,842 to Strang et al., and U.S. Patent No. 5,711,320 to Martin, the disclosures of which are incorporated herein by reference in their entirety. Preferred casing materials include water, sugars and syrups (e.g., sucrose, glucose, and high fructose corn syrup), humectants (e.g., glycerin or propylene glycol), and flavorings (e.g., cocoa and licorice). These additional ingredients also include top dressing materials (e.g., flavoring materials such as menthol). See, for example, U.S. Pat. No. 4,449,541 to Mays et al., the disclosures of which are incorporated herein by reference in their entirety. Additional materials that can be added include those disclosed in U.S. Pat. No. 4,830,028 to Lawson et al. and U.S. Pat. No. 8,186,360 to Marshall et al., the disclosures of which are incorporated herein by reference in their entirety.

[0065] For example, in some embodiments, the aerosol delivery component is provided with a substrate having an aerosol precursor composition associated therewith. In this example, the aerosol precursor composition includes one or more different components, such as a polyhydric alcohol (e.g., glycerin, propylene glycol, or mixtures thereof). Representative types of additional aerosol precursor compositions are described in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al., U.S. Pat. No. 5,101,839 to Jakob et al., PCT Publication WO 98 / 57556 to Biggs et al., and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, RJ Reynolds Tobacco Company Monograph (1988), the disclosures of which are incorporated herein by reference. In some embodiments, the aerosol delivery component generates a visible aerosol when sufficient heat is applied (and optionally cooled by air), and the aerosol delivery component generates a "smoke-like" aerosol. In other aspects, the aerosol delivery components generate an aerosol that is substantially invisible, but whose presence is recognized by other characteristics such as flavor or texture. Thus, the nature of the aerosol generated varies depending on the particular components of the aerosol delivery components. The aerosol delivery components are chemically simple compared to the chemistry of smoke generated by burning tobacco.

[0066] A wide variety of flavoring agents or materials that change the sensory or organoleptic properties or characteristics of the mainstream aerosol of the smoking article are suitable for use. In some embodiments, such flavoring agents are provided from sources other than tobacco and are natural or artificial in nature. Of particular interest are flavoring agents that are applied to or incorporated into the aerosol delivery component and / or the area of ​​the smoking article where the aerosol is generated. In some embodiments, such agents are provided directly to the heating cavity or area adjacent to the heat source or provided together with the aerosol delivery component. Exemplary flavoring agents 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 flavors and flavor packages of the type and characteristics conventionally used in cigarette, cigar, and pipe tobacco flavorings. Syrups such as high fructose corn syrup are also suitable for use. Flavoring agents also include acidic or basic properties (e.g., organic acids such as levulinic acid, succinic acid, and pyruvic acid). Flavoring agents can be combined with elements of the aerosol delivery component as desired. Exemplary plant-derived compositions that are suitable are disclosed in U.S. Patent No. 9,107,453 and U.S. Patent Application Publication No. 2012 / 0152265, both to Dube et al., the disclosures of which are incorporated herein by reference in their entireties. The selection of such additional ingredients can vary based on factors such as the sensory characteristics desired in the smoking article, and the present disclosure is intended to encompass any such additional ingredients that would be readily apparent to one skilled in the art of tobacco and tobacco-related or tobacco-derived products.See Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972), the disclosures of which are incorporated herein by reference in their entireties.

[0067] Any of the flavorings, casings, and other materials that are useful in combination with tobacco materials to affect their sensory properties, including the sensory properties as described herein, can be combined with the aerosol delivery component. In particular, organic acids can be incorporated into the aerosol delivery component to affect the flavor, sensory, or organoleptic properties of agents such as nicotine that can be combined with the aerosol delivery component. For example, organic acids such as levulinic acid, lactic acid, and pyruvic acid are included in the aerosol delivery component with nicotine in amounts up to equimolar to nicotine (based on total organic acid content). Any combination of organic acids is suitable. For example, in some examples, the aerosol delivery component includes about 0.1 to about 0.5 moles of levulinic acid per mole of nicotine, about 0.1 to about 0.5 moles of pyruvic acid per mole of nicotine, about 0.1 to about 0.5 moles of lactic acid per mole of nicotine, or combinations thereof, up to a concentration where the total amount of organic acid present is equimolar to the total amount of nicotine present in the aerosol delivery component. Various additional examples of organic acids used to generate the aerosol delivery components are described in U.S. Patent Application Publication No. 2015 / 0344456 to Dull et al., which is incorporated by reference in its entirety.

[0068] In yet another embodiment of the present disclosure, the aerosol delivery component is configured as an extruded structure and / or matrix that includes or consists essentially of tobacco, tobacco-related materials, glycerin, water, and / or binder materials, although certain formulations do not include binder materials. The binder materials are any binder materials commonly used in tobacco formulations, including, for example, carboxymethylcellulose (CMC), gums (e.g., guar gum), xanthan, pullulan, and / or alginates. According to some embodiments, the binder materials included in the aerosol delivery component are configured to substantially maintain the structural shape and / or integrity of the aerosol delivery component. Various representative binders, binder properties, binder uses, and binder amounts are described in U.S. Pat. No. 4,924,887 to Raker et al., which is incorporated herein by reference in its entirety.

[0069] In another embodiment, the aerosol delivery component includes a plurality of microcapsules, beads, granules, etc., having tobacco-related material. For example, a typical microcapsule is approximately spherical in shape and has an outer covering or shell that includes a liquid central region, such as a tobacco-derived extract. In some embodiments, the aerosol delivery component includes a plurality of microcapsules, each formed in a hollow cylindrical shape. In one embodiment, the aerosol delivery component includes a binder material configured to maintain the structural shape and / or integrity of the plurality of microcapsules formed in a hollow cylindrical shape.

[0070] In some embodiments, the aerosol delivery component is configured as an extruded material, as described in U.S. Patent Application Publication No. 2012 / 0042885 to Stone et al., which is incorporated herein by reference in its entirety. In yet another embodiment, the aerosol delivery component comprises an extruded structure and / or substrate formed from marmarized and / or non-marmarized tobacco. Marmarized tobacco is known, for example, from U.S. Patent No. 5,105,831 to Banerjee et al., which is incorporated herein by reference in its entirety. Marmarized tobacco comprises about 20 to about 50 percent (by weight) of a tobacco blend in powder form, along with glycerol (about 20 to about 30 percent by weight), calcium carbonate (generally about 10 to about 60 percent by weight, often about 40 to about 60 percent by weight), in addition to the binders and / or flavorings described herein.

[0071] The aerosol delivery component takes various forms based on the various amounts of materials used in the aerosol delivery component. For example, useful aerosol delivery components include up to about 98% by weight, up to about 95% by weight, or up to about 90% by weight of tobacco and / or tobacco materials. Useful aerosol delivery components also include up to about 25% by weight, about 20% by weight, or about 15% by weight of water, particularly about 2% to about 25% by weight, about 5% to about 20% by weight, or about 7% to about 15% by weight of water. Flavors and the like (including, for example, drugs such as nicotine) comprise up to about 10% by weight, up to about 8% by weight, or up to about 5% by weight of the aerosol delivery component.

[0072] Additionally or alternatively, the aerosol delivery component is configured as an extruded structure and / or substrate that includes or consists essentially of tobacco, glycerin, water and / or binder material and is further configured to substantially maintain the structure of the aerosol delivery component throughout the aerosol generation process. That is, the aerosol delivery component is configured to substantially maintain its shape throughout the aerosol generation process (i.e., the aerosol delivery component does not continuously deform under applied shear stress). Although the aerosol delivery component includes liquid and / or some moisture content, the aerosol delivery component remains substantially solid throughout the aerosol generation process and substantially maintains structural integrity throughout the aerosol generation process. Exemplary tobacco and / or tobacco-related materials suitable for the substantially solid aerosol delivery component are described in U.S. Patent Application Publication No. 2015 / 0157052 to Ademe et al., U.S. Patent Application Publication No. 2015 / 0335070 to Sears et al., U.S. Patent No. 6,204,287 to White, and U.S. Patent No. 5,060,676 to Hearn et al., all of which are each incorporated by reference in their entireties herein.

[0073] Additionally or alternatively, the aerosol delivery component is configured as a liquid capable of generating an aerosol upon application of sufficient heat, having ingredients commonly referred to as "smoke juice," "e-liquid," and "e-juice." Exemplary formulations of aerosol-generating liquids are described in U.S. Patent Publication No. 2013 / 0008457 to Zheng et al., the disclosure of which is incorporated herein by reference in its entirety.

[0074] The amount of aerosol delivery component used in the smoking article is such that the article exhibits acceptable sensory and organoleptic properties, as well as desirable performance properties.For example, it is highly preferred that sufficient aerosol precursor composition, such as glycerin and / or propylene glycol, is used in the aerosol delivery component to generate a visible mainstream aerosol that resembles the appearance of tobacco smoke in many respects.Typically, the amount of aerosol precursor composition incorporated in the aerosol delivery component of the smoking article is in the range of about 1.5 grams or less, about 1 gram or less, or about 0.5 grams or less.

[0075] In some additional embodiments, the smoking article disclosed herein includes one or more indicators or indicia. Such indicators or indicia include lights (e.g., light-emitting diodes) that provide an indication of multiple aspects of the use of the article of the present invention. In yet another example, an LED indicator is disposed at the distal end of the smoking article to mimic the color change seen when a user lights and draws on a conventional cigarette. Other indicators of operation are also encompassed by the present disclosure. For example, visual indicators of operation also include changes in color or intensity of light to indicate the progress of the smoking experience. Tactile indicators of operation and audio indicators of operation are also encompassed by the present disclosure. Furthermore, combinations of such indicators of operation are also suitable for use in a single smoking article. According to another embodiment, the smoking article includes one or more indicators or indicia, such as a display configured to provide information corresponding to the operation of the smoking article, such as the amount of power remaining in the power source, the progress of the smoking experience, an indication corresponding to the activation of the heat source, and the like.

[0076] Although various materials for use in smoking articles according to the present disclosure are described above, such as heaters, batteries, capacitors, switching components, aerosol delivery components, aerosol precursor compositions, etc., the present disclosure should not be construed as being limited to only the exemplified embodiments, but rather, a person skilled in the art will recognize, based on the present disclosure, similar components in the art that are interchangeable with any particular component of the present disclosure. For example, U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor associated with the mouth end of the device that detects a user's lip movement associated with a puff and subsequently causes heating; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow to a heat load array in response to a drop in pressure through a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. discloses a receptacle in a smoking device that includes an identifier that detects non-uniformity in infrared transparency of an inserted component and a controller that executes a detection routine when a component is inserted into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer et al. describes defined possible power cycles having a number of different phases; and U.S. Pat. No. 5,934,289 to Watkins et al. No. 5,954,979 to Counts et al. discloses means for varying the resistance of draw through a smoking device; U.S. Pat. No. 6,803,545 to Blake et al. discloses particular battery configurations for use in smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses computer interface means for a smoking device which facilitates charging and allows computer control of the device; and U.S. Pat. No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device, all of the foregoing disclosures are incorporated herein by reference in their entireties.Additional examples of components related to electronic aerosol delivery articles, and additional examples disclosing materials or components suitable for use in the articles of the present invention include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,204,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513,253 to Kobayashi, U.S. Pat. No. 7,513,253 to Hamano, U.S. Pat. No. 7,896,006, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. Nos. 8,156,944 and 8,375,957 to Hon, U.S. Pat. Appl. Pub. Nos. 2006 / 0196518 and 2009 / 0188490 to Hon, U.S. Pat. No. 8,794,231 to Thorens et al., U.S. Pat. Nos. 8,915,254 and 8,925,555 to Monsees et al., U.S. Pat. No. 8,851,083 and U.S. Pat. Appl. Pub. No. 2010 / 0024834 to Oglesby et al., U.S. Pat. Appl. Pub. No. 2010 / 0307518 to Wang, and WO 2010 / 091593 to Hon. The various materials disclosed by the aforementioned documents may be incorporated in the devices of the present invention in a variety of ways, and all of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0077] As will be described in detail below, smoking articles according to the present disclosure may take various forms, but the use of the smoking article by a consumer will be similar in scope. The above description of the use of the smoking article is applicable to the various forms described, with minor modifications that will be apparent to those skilled in the art in light of the further disclosure provided herein. However, the above description of use is not intended to limit the use of the article of the present invention, but is provided to meet all necessary requirements of the disclosure herein.

[0078] 1A and 1B, a first embodiment of a smoking article is disclosed. The smoking article 100 advantageously provides a two-component smoking article utilising two separable components, as compared to three or more separable components. The two separable components are joined together with an outer wrap, which will be described in further detail below, for advantageously simplified assembly for the consumer.

[0079] In some embodiments, the smoking article 100 includes a heat source 102 configured to generate heat upon ignition of the heat source. The heat source 102, for example, has a generally cylindrical shape and includes a combustible fuel element incorporating a combustible carbonaceous material. Such carbonaceous materials generally have a high carbon content. Preferred carbonaceous materials are composed primarily of carbon and typically have a carbon content of greater than about 60%, generally greater than about 70%, often greater than about 80%, and frequently greater than about 90% on a dry weight basis.

[0080] In some examples, the heat source 102 incorporates elements other than combustible carbonaceous material (e.g., tobacco components such as powdered tobacco or tobacco extract; flavorings; salts such as sodium chloride, potassium chloride, and sodium carbonate; heat stable graphite fibers; iron oxide powder; glass filaments; powdered calcium carbonate; alumina granules; ammonia sources such as ammonia salts; and / or binders such as guar gum, ammonium alginate, and sodium alginate). In some embodiments, the heat source 102 has a length of about 12 mm and an overall outer diameter of about 4.2 mm. In other embodiments, the heat source 102 is extruded or compounded with ground or powdered carbonaceous material, and has a mass of about 0.5 g / cm on a dry weight basis.3 Ultra, often around 0.7 g / cm 3 Ultra-frequently about 1g / cm 3 See, for example, the types of fuel source components, formulations and designs described in U.S. Patent No. 5,551,451 to Riggs et al. and U.S. Patent No. 7,836,897 to Borschke et al., which are incorporated by reference in their entireties.

[0081] Thus, as shown in Figures 1A and 1B, the heat source 102 comprises an extruded monolithic carbonaceous material that defines one or more channels 104 extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material. However, in other aspects, the heat source 102 includes alternative configurations, such as a generally circular cross-section, or the heat source 102 defines longitudinal grooves or slits extending longitudinally from a first end of the extruded monolithic carbonaceous material to its opposing second end. Furthermore, in some additional aspects, the heat source 102 comprises a foamed carbon monolith formed in a foaming process of the type disclosed in U.S. Patent No. 7,615,184 to Lobovsky, which is incorporated herein by reference. This embodiment provides advantages with respect to the reduced time it takes to ignite the heat source 102. In another embodiment, the heat source 102 is co-extruded with a layer of insulation (not shown), thereby reducing manufacturing time and costs. Still other embodiments of the fuel element include carbon fiber of the type described in U.S. Pat. No. 4,922,901 to Brooks et al., or other heat source embodiments such as those disclosed in U.S. Patent Application Publication No. 2009 / 0044818 to Takeuchi et al., each of which is incorporated herein by reference.

[0082] The smoking article 100, in some embodiments, further comprises a first substrate 106 having opposing first and second ends. As shown in FIG. 1A, the first end of the first substrate 106 is fixedly engaged with the heat source 102 in a variety of ways, including by gluing, welding, screwing or otherwise joining to the heat source 102. The heat source 102 and the first substrate 106, in some embodiments, have substantially similar shapes and / or measurements, such that upon fixed engagement, the two form an integral unit (e.g., a cylinder). In this manner, the first substrate 106 and the heat source 102 form the first component of a two-component design of the smoking article 100.

[0083] The first substrate 106, in some embodiments, comprises a material having various inherent characteristics or properties. For example, the first substrate 106 comprises a plasticized material in the form of rayon or regenerated cellulose. As another example, viscose (commercially available as VISIL®), a regenerated cellulose product incorporating silica, is suitable. A preferred carbon fiber comprises at least 95 percent or more carbon. Similarly, natural cellulose fibers such as cotton are suitable and are preferably infused or otherwise treated with silica, carbon or metal particles to enhance flame retardant properties and minimize outgassing of any undesirable outgassing components that would adversely affect flavor (particularly to minimize the possibility of any harmful outgassing products). Cotton can be treated, for example, with boric acid or various organophosphate compounds to provide the desired flame retardant properties by dipping, spraying, or other techniques known in the art, as known in the art. These fibers can also be treated (e.g., coated by dipping, spraying or vapor deposition, impregnated or both) with organic or metallic nanoparticles to impart desired flame retardant properties without undesirable outgassing or melt-type behavior.

[0084] In this manner, the first substrate 106 has an aerosol precursor composition associated with it (i.e., treated, coated, impregnated, etc.). As discussed herein, the aerosol precursor composition includes a humectant, such as, for example, propylene glycol, glycerin, and / or at least one flavoring agent, as well as a flame retardant (e.g., diammonium phosphate and / or another salt) configured to help prevent ignition, pyrolysis, combustion, and / or charring of the aerosol delivery components associated with the first substrate 106 by the heat source 102.

[0085] In some embodiments, the smoking article 100 further includes an aerosol delivery component 108 having opposing first and second ends. The aerosol delivery component 108 includes a longitudinally extending axis defined centrally between each of the opposing first and second ends. The cross-section of the aerosol delivery component 108 is, in some embodiments, symmetrical about the axis. For example, the cross-section of the aerosol delivery component 108 is generally circular such that the aerosol delivery component defines a generally cylindrical shape extending between its opposing first and second ends. However, in other embodiments, the aerosol delivery component 108 defines a generally non-circular cross-section such that the aerosol delivery component 108 defines a generally non-cylindrical shape between its opposing first and second ends. Otherwise, in other instances, the aerosol delivery component 108 has an asymmetric cross-section about the axis.

[0086] Each end of the aerosol delivery component 108, in some embodiments, is axially aligned with an adjacent element. For example, the first end of the aerosol delivery component 108 is configured to be coaxially aligned with the second end of the first substrate 106 when they are engaged. In this manner, the aerosol delivery component 108 is the second component in the two-component design of the smoking article 100. Thus, when the first end of the aerosol delivery component 108 is engaged with the second end of the first substrate 106, the smoking article 100 is assembled for use.

[0087] As shown in FIG. 1B, an outer wrap material 110 is provided to engage or otherwise join a first end of the aerosol delivery component 108 to a second end of the first substrate 106. In some embodiments, the outer wrap material 110 is configured to surround, e.g., coaxially surround, the heat source 102, the first substrate 106 engaged to the heat source 102 about its first end, and the aerosol delivery component 108 engaged to the second end of the first substrate 106. The outer wrap material 110 is configured to be held in the wrapped position in any manner, including with adhesives, fasteners, etc., to allow the outer wrap material 110 to remain in the wrapped position. Otherwise, in some other embodiments, the outer wrap material 110 is configured to be removable, if desired. For example, with the outer wrap material 110 held in the wrapped position, the outer wrap material 110 can then be removed from the heat source 102, removed from the first substrate 106 engaged to the heat source 102 about its first end, and removed from the aerosol delivery component 108 engaged to a second end of the first substrate 106. In this example, adhesives, fasteners, etc. are removed and the outer wrap material 110 does not wrap around it.

[0088] In some aspects, the outer wrap material 110 includes a liner 112 disposed adjacent to the heat source 102, the first substrate 106, and the aerosol delivery component 108. In such examples, the outer wrap material 110 and the liner 112 are separate materials that are provided together (e.g., glued, fused, or otherwise joined together as a laminate). In other examples, the outer wrap material 110 and the liner 112 are the same material. In either case, the liner 112 is configured in these examples to thermally regulate the conduction of heat generated by the ignited heat source 102 radially outward of the liner 112. To do so, the liner 112, in some aspects, includes a material selected from the group consisting of foil, graphene, graphite, and aluminum oxide. In some embodiments, depending on the materials of the outer wrap material 110 and / or the liner 112, a thin layer of insulation may be provided radially outward of the outer wrap material 110. Thus, the outer wrap material 110, in some embodiments, advantageously provides a method of engaging two separate components of the smoking article 100 while also providing a method of promoting axial heat transfer therealong but limiting radially outward heat conduction.

[0089] In some embodiments, the second substrate 114 is provided with the aerosol delivery component 108. Specifically, the second substrate 114 has an aerosol precursor composition associated with it (i.e., treated, coated, impregnated, etc.) and disposed around a first end of the aerosol delivery component 108. The aerosol precursor composition associated with the second substrate 114 is substantially the same as or similar to the aerosol precursor composition associated with the first substrate 106. Otherwise, in other embodiments, the first substrate 106 has an aerosol precursor composition associated with it that is different from the aerosol precursor composition associated with the second substrate 114.

[0090] Additionally, the second substrate 114 comprises a material that is substantially similar or the same as the first substrate 106. Alternatively, in other embodiments, the first substrate 106 and the second substrate 114 comprise different materials. In some examples, the first substrate 106 and the second substrate 114 comprise a cellulose acetate material, and the aerosol precursor composition comprises glycerin coated on the cellulose acetate of the first substrate 106 and the second substrate 114.

[0091] A second end of the aerosol delivery component 108, opposite the first end engaged to the second end of the first substrate 106, includes a mouthpiece 116 having a filter material 118. Components of an aerosol generated by heat from the heat source 102 during use of the smoking article 100 are drawn through the mouthpiece 116 and the filter material 118 while a user draws on the mouthpiece 116.

[0092] FIG. 1A, for example, shows a cylindrical housing 120 defining a cavity 122 for receiving and holding a tobacco material 124, the cavity being disposed between the second substrate 114 and the mouthpiece 116 of the aerosol delivery component 108. The tobacco material 124, in some embodiments, comprises tobacco-containing beads, tobacco shreds, tobacco strips, reconstituted tobacco material pieces, or combinations thereof. Thus, the tobacco material 124 is disposed between the second substrate 114 and the mouthpiece 116 in a "dry" manner, such that the tobacco material 124 is not directly combined with the aerosol precursor composition, as compared to other products in which dry heat from a heat source aerosolizes an aerosol precursor composition directly combined with the tobacco material. Instead, the aerosol precursor composition is configured to generate an aerosol in response to heat generated by an ignited heat source 102, combined with the first and second substrates 106, 114. The aerosol is then drawn through the tobacco material 124 and through the filter material 118 of the mouthpiece 116 in response to drawing on the mouthpiece 116 .

[0093] Specifically, ignition of the heat source 102 results in aerosolization of the aerosol precursor composition bound to each of the first substrate 106 and the second substrate 114. Preferably, the elements of the first substrate 106 and the second substrate 114 are not significantly pyrolyzed (e.g., carbonized, charred or burned). The aerosolized components are carried by air drawn through an aerosol-generation region (not shown). The aerosol so formed is drawn through the filter material 118 and into the mouth of the smoker.

[0094] Thus, the second component of the smoking article, i.e., the aerosol delivery component 108, is advantageously formed from the integration of the mouthpiece 116 and filter material 118 with the second substrate 114 and the tobacco material 124. The integration of these components of the aerosol delivery component 108 reduces the complexity of the assembly of the aerosol delivery component 108 with the first component, i.e., the heat source 102 and the first substrate 106. Thus, the first component (the heat source 102 and the first substrate 106) is simply joined together with the second component (the aerosol delivery component 108) by the outer wrap material 110. As shown in FIG. 1B, the outer wrap material 110 is configured to surround the first and second components, such that the smoking article 100 is formed like a cigar or cigarette to mimic the consumer's smoking experience while reducing the traditional number of smoking article components from three to two.

[0095] 2A-2D, a second embodiment of a smoking article is disclosed. The smoking article 200 of Figure 2D advantageously provides a rechargeable aerosol generation module 202 configured to be received within a tubular casing 204 constructed from an insulating material. The insulating material of the tubular casing 204 advantageously reduces the external temperature of the rechargeable aerosol generation module 202 compared to a conventional aerosol generation module 202 lacking an insulating casing.

[0096] More specifically, in some embodiments, the aerosol generating module 202 of the smoking article 200 includes a heat source 206 configured to generate heat upon ignition of the heat source. The heat source 206 includes a combustible fuel element having a generally cylindrical shape and incorporating a combustible carbonaceous material, for example, similar to that described above with respect to the heat source 102. Thus, as shown in FIG. 2A, the heat source 206 includes an extruded monolithic carbonaceous material defining one or more channels 208 extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material. However, in other embodiments, the heat source 206 includes alternative configurations, such as a generally circular cross-section, or the heat source 206 defines longitudinal grooves or slits extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material.

[0097] The aerosol generation module 202 further includes an aerosol delivery component 210, which in some embodiments has opposing first and second ends. The aerosol delivery component 210 includes a longitudinally extending axis defined centrally between each of the opposing first and second ends. The cross-section of the aerosol delivery component 210 is symmetrical about the axis in some embodiments. For example, the cross-section of the aerosol delivery component 210 is generally circular such that the aerosol delivery component defines a generally cylindrical shape extending between its opposing first and second ends. In this example, as shown in FIG. 2A, the aerosol delivery component 210 includes a tubular member 212. However, in other embodiments, the aerosol delivery component 210 defines a generally non-circular cross-section such that the aerosol delivery component 210 defines a generally non-cylindrical shape between its opposing first and second ends. In these examples, the aerosol delivery component 210 includes a non-tubular member (not shown). Alternatively, in other examples, the aerosol delivery component 210 has an asymmetric cross-section about the axis.

[0098] The tubular member 212 of the aerosol delivery component 210 comprises a material that is substantially rigid or inflexible along its longitudinal axis, regardless of cross-section. Additionally, the tubular member 212 comprises a material that is essentially biodegradable. Thus, it is desirable for the tubular member 212 of the aerosol delivery component 210 to comprise extruded carbon or graphite, such that the tubular member 212 exhibits rigidity while still being essentially biodegradable. As shown in FIG. 2A, the tubular member 212 is a hollow member that defines a cavity extending between opposing first and second ends. In some instances, for example, the tubular member 212 is a hollow cylinder constructed from extruded carbon or graphite.

[0099] Each end of the aerosol delivery component 210, in some embodiments, axially aligns with an element of the aerosol generation module 202 when assembled with the aerosol generation module. For example, a first end of the aerosol delivery component 210 is axially engageable with the heat source 206. In this example, the first end of the aerosol delivery component 210 is engageable with the heat source 206 by the packaging material 214. FIG. 2B shows the packaging material 214 configured to surround at least the heat source 206 and the aerosol delivery component 210 of the aerosol generation module 202, for example, to engage the heat source 206 with the first end of the aerosol delivery component 210. The packaging material 214 is configured to be held in a wrapped position around the heat source 206 and the aerosol delivery component 210 in any number of ways, including with adhesives, fasteners, and the like, to allow the packaging material 214 to remain in a fixed position.

[0100] 2A, in one example, the aerosol delivery component 210 includes tobacco material 216 combined with an aerosol precursor composition and disposed within a tubular member 212. More specifically, the interior cavity of the tubular member 212 is configured to receive the tobacco material 216 combined with the aerosol precursor composition such that the tobacco material 216 combined with the aerosol precursor composition is packed, inserted, poured, or otherwise disposed within the tubular member 212 between opposing first and second ends. The tobacco material 216, in some embodiments, includes tobacco-containing beads, shredded tobacco, tobacco strips, reconstituted tobacco material pieces, or combinations thereof. The aerosol precursor composition combined with the tobacco material includes, for example, a humectant, such as propylene glycol, glycerin, and / or at least one flavoring agent, as well as a flame retardant (e.g., diammonium phosphate and / or another salt) configured to help prevent ignition, pyrolysis, combustion and / or charring of the tobacco material 216 and / or wrapping material 214 by the heat source 206.

[0101] 1A and 1B, the smoking article 200 utilizes tobacco material 216 that is coated with an aerosol precursor composition prior to disposing the tobacco material 216 within the tubular member 212. Alternatively, the tobacco material 216 is disposed within the tubular member 212 and then coated with the aerosol precursor composition. In either case, the tobacco material 216 becomes "wet" when heated by the heat source 206, such that the aerosol precursor composition combined with the tobacco material 216 is configured to generate a strong and highly flavorful aerosol in response to heat generated by the heat source 206.

[0102] The mouthpiece 218 is engaged to a second end of the aerosol delivery component 210 axially opposite the first end of the aerosol delivery component engaged to the heat source 206. The mouthpiece 218 is configured to receive an aerosol therethrough in response to suction applied to the mouthpiece 218 by a user. The mouthpiece 218 is fixedly engaged to the aerosol delivery component 210 in some embodiments. For example, adhesives, bonds, welding, or the like are suitable for fixedly engaging the mouthpiece 218 to the aerosol delivery component 210. In one example, the mouthpiece is ultrasonically welded and sealed to the second end of the aerosol delivery component 210.

[0103] Mouthpiece 218, in some embodiments, further includes filter material 220 configured to receive aerosol through the mouthpiece in response to suction applied to mouthpiece 218. Filter material 220, in some embodiments, is provided as a circular disk disposed radially and / or longitudinally between the second end of tubular member 212 and mouthpiece 218. In this manner, upon drawing on mouthpiece 218, filter material 220 receives aerosol flowing through tubular member 212 of aerosol delivery component 210.

[0104] In yet another embodiment, the aerosol delivery component 210 includes an annular portion 222 extending around the second end of the tubular member 212 and configured to engage the mouthpiece 218. The annular portion 222 is configured to act as a sealing mechanism between the mouthpiece 218 and the tubular member 212 of the aerosol delivery component 210 to prevent ambient air from entering a flow path defined along the longitudinal axis of the aerosol generation module 202. The annular portion 222, in some embodiments, has a diameter larger than the diameter of the tubular member 212, but small enough to be sealingly received within the mouthpiece 218. The annular portion 222 is configured to be fixedly attached to the second end of the tubular member 212 by adhesive, bond, welding, or the like. For example, the annular portion 222 is ultrasonically welded or sealed to the mouthpiece 218 or to the second end of the tubular member 212. In such embodiments, mouthpiece 218 with annular portion 222 welded or sealed thereto is configured such that annular portion 222 receives the second end of tubular member 212. In other such embodiments, mouthpiece 218 is configured to receive annular portion 222 therein, with the annular portion being welded or sealed to the second end of tubular member 212. When filter material 220 is included within the mouthpiece, filter material 220 is disposed radially and / or longitudinally between annular portion 222 and mouthpiece 218.

[0105] To make the aerosol generation module 202 essentially biodegradable, at least one of the annular portion 222 and the mouthpiece 218 includes a biodegradable material. For example, at least one of the annular portion 222 and the mouthpiece 218 includes a biodegradable plastic, such as polyhydroxyalkanoate (PHA). In various embodiments, the filter material 220 includes a biodegradable material or includes a non-biodegradable material, such as cellulose acetate, that is easily removed prior to composting the aerosol generation module 202.

[0106] 2C illustrates an exemplary embodiment of the tubular casing 204 in further detail. The tubular casing 204 is constructed of an insulating material. For example, the insulating material of the tubular casing 204 may include ceramic materials, graphene, graphite, and the like. Otherwise, the insulating material of the tubular casing 204 is an insulating material that can distribute and dissipate heat generated from the heat source 206 so that the temperature of the exterior surface of the tubular casing 204, particularly near the heat source 206, does not become excessively hot. The configuration of the tubular casing 204 also reduces the possibility of scorching of its exterior surface near the heat source 206.

[0107] The tubular casing 204 is configured, in some embodiments, to be capable of receiving therein at least the heat source 206 and the aerosol delivery component 210 of the aerosol generation module 202 in a coaxial relationship (i.e., arranged in series) with one another. When the packaging material 214 is utilized to engage the heat source 206 with a first end of the aerosol delivery component 210, the tubular casing 204 is configured to removably receive at least the heat source 206 and the aerosol delivery component 210 of the aerosol generation module 202 surrounded by the packaging material 214. Thus, the tubular casing 204 is designed, sized, and / or shaped to be larger than each of at least the heat source 206 and the aerosol delivery component 210 of the aerosol generation module 202 that are not or otherwise enveloped in the packaging material 214.

[0108] 2D shows a tubular casing 204 having at least the heat source 206 and the aerosol delivery component 210 of the aerosol generation module 202 received therein in a coaxial relationship with one another. The heat source 206 and the aerosol delivery component 210 of the aerosol generation module 202 are configured to slide into the open end of the tubular casing 204. Thus, upon receiving at least the heat source 206 and the aerosol delivery component 210 of the aerosol generation module 202 therein, the tubular casing 204 is configured to thermally regulate the conduction (i.e., radially outward) of heat generated by the ignited heat source 206 through the tubular casing. Specifically, ignition of the heat source 206 results in aerosolization of the aerosol precursor composition combined with the tobacco material 216 disposed within the tubular member 212. Preferably, elements of the tobacco material 216 are not significantly pyrolyzed (e.g., carbonized or combusted). The aerosolized components are thus carried by the air drawn through the aerosol-generating region (i.e., the tobacco material 216). The aerosol so formed is drawn through the filter material 220 and into the smoker's mouth.

[0109] Advantageously, the aerosol generation module 202 and the tubular casing 204 are provided together in a packaged unit. For example, the packaged unit includes one or more aerosol generation modules 202 configured to be utilized by a smoker and then discarded (e.g., composted), whereas the tubular casing 204 is configured to be reused with each new aerosol generation module 202. In this example, the mouthpiece 218 of each aerosol generation module 202 is configured to be removably engaged with the tubular casing 204 via various engagement mechanisms, including snap-fit ​​engagement, press-fit engagement, threaded engagement, adhesive, bond, welding, etc. Thus, a user can engage the mouthpiece 218 of a new aerosol generation module 202 with the tubular casing 204 before igniting the heat source 206.

[0110] 3A-3C, a third embodiment of a smoking article is disclosed. The smoking article 300 of Figure 3C advantageously provides a power source configured to heat a small amount of tobacco material so as to reduce the overall heat generated during use compared to conventional smoking articles.

[0111] More specifically, an exploded view of the smoking article 300 is shown in FIG. 3A. The smoking article 300, in some embodiments, includes a power source 302. In some examples, the power source takes a variety of forms. Preferably, the power source 302 is capable of providing sufficient power to rapidly provide aerosol formation with the tobacco material and to power the article 300 throughout a desired duration of use. The power source 302 is preferably sized to fit conveniently within the article 300 so that the article is easily handled. Additionally, the preferred power source 302 is sufficiently lightweight so as not to detract from the desired smoking experience.

[0112] The power source 302, in some embodiments, is an electrical power source configured to generate, generate, or otherwise provide electrical power. For example, the power source 302 desirably includes a rechargeable lithium ion battery (e.g., a rechargeable lithium manganese dioxide battery). In particular, lithium polymer batteries can be used because such batteries enhance safety. Other types of batteries can also be used, such as N50-AAA CADNICA nickel cadmium batteries. Further examples of batteries that can be used in accordance with the present disclosure are described in U.S. Pat. No. 9,484,155 to Peckerar et al., the disclosure of which is incorporated herein by reference in its entirety. In some embodiments, thin film batteries are used in certain embodiments of the present disclosure. Any of these batteries or combinations thereof can be used for the power source, but rechargeable batteries are preferred due to the cost and disposal considerations associated with disposable batteries. In embodiments in which disposable batteries are provided, the smoking article 300 includes access for removing and replacing the battery. Alternatively, in embodiments in which a rechargeable battery is used, the smoking article 300 includes charging contacts (not shown) for interacting with corresponding contacts of a conventional charging unit that obtains power from a standard 120 volt AC wall outlet or other source, such as an automobile's electrical system, or a separate portable power source, including a USB connection. In some embodiments, an arrangement for recharging the battery is provided, for example in a portable charging case that includes a relatively large battery unit that provides multiple charges for the relatively small battery present in the smoking article 300. Alternatively, in some embodiments, the smoking article 300 includes elements for providing a contactless inductive recharging system, whereby the smoking article 300 is charged without being physically connected to an external power source. Thus, the smoking article 300, in some examples, includes elements for facilitating the transfer of energy from an electromagnetic field to a rechargeable battery within the smoking article 300.

[0113] In some embodiments, the power source 302 also includes one or more capacitors. For example, the power source 302 includes any number of batteries and / or a combination of capacitors. In some embodiments, the power source 302 includes at least one battery and at least one capacitor. The capacitor can be discharged faster than the battery and can be charged between puffs, allowing the battery to discharge into the capacitor at a slower rate than if it were used to directly power the heat source. For example, a supercapacitor, i.e., an electric double layer capacitor (EDLC), is arranged separately from or in combination with the battery. If used alone, the supercapacitor is recharged before each use of the smoking article 300. Thus, a charger component can be attached to the smoking article 300 between uses to replenish the supercapacitor.

[0114] The smoking article 300, in some embodiments, further includes various power management software, hardware and / or other electronic control components (not shown). For example, such software, hardware and / or electronic control may include functions such as performing battery charging, detecting battery charging and discharging states, performing power saving operations, and preventing unintentional or over-discharging of the battery.

[0115] Regardless of its implementation, in some embodiments, as shown in FIG. 3A, the power supply 302 has opposing first and second ends that define an axis extending through the power supply. The cross-section of the power supply 302 is, in some embodiments, symmetrical about the axis. For example, the cross-section of the power supply 302 is generally circular such that the power supply 302 defines a generally cylindrical shape extending between its opposing first and second ends. In this example, as shown in FIG. 3A, the power supply 302 is housed in a tubular control enclosure 304 having opposing first and second ends and defining an axis therebetween. In this example, the power supply 302 is disposed within the tubular control enclosure 304 such that the power supply 302 and the tubular control enclosure 304 are coaxially aligned with one another.

[0116] However, in other embodiments, the power source 302 and / or the tubular control enclosure 304 define a generally non-circular cross-section such that the power source 302 and / or the tubular control enclosure 304 defines a generally non-cylindrical shape between its opposing first and second ends. In these examples, the power source 302 and / or the tubular control enclosure 304 include a non-tubular member (not shown). Otherwise, in other examples, the power source 302 and / or the tubular control enclosure 304 has an asymmetric cross-section about an axis.

[0117] The smoking article 300, in some embodiments, further includes a heat source 306 in communication with the second end of the power source 302 and extending along an axis. The heat source 306 is configured to generate conductive heat, radiant heat, inductive heat, etc. in response to power received from the power source 302.

[0118] In some embodiments, the heat source 306 implements an electrically conductive material; such materials useful as heat sources have low mass, low density, and moderate resistivity, and are thermally stable at temperatures experienced during use. Useful heat sources heat and cool rapidly, and therefore use energy efficiently. Rapid heating results in nearly instant aerosolization, while rapid cooling (i.e., to a temperature below the volatilization temperature of the aerosol delivery component / component / composition / material) prevents substantial volatilization (and thus waste) during periods when aerosol formation is not desired. Such heat sources also allow for relatively precise control of the temperature range, especially when time-based current control is used.

[0119] Thus, in some embodiments, for example, the heat source 306 includes an electrically conductive material (i.e., for resistive heating) to facilitate rapid heating and cooling of the solid tobacco material disposed adjacent to the electrically conductive material. Exemplary electrically conductive materials suitable for the heat source 306 are preferably chemically non-reactive with the material being heated so as not to adversely affect the flavor or content of the aerosol or vapor produced. Exemplary non-limiting materials suitable as electrically conductive materials include carbon, graphite, carbon / graphite composites, metals, metal and non-metal carbides, ceramics, nitrides, silicides, intermetallic compounds, cermets, alloys, and metal foils. In particular, refractory materials are useful. A variety of different materials can be mixed to achieve the desired properties of resistivity, mass, and thermal conductivity. In certain embodiments, metals that can be utilized include, for example, nickel, chromium, alloys of nickel and chromium (e.g., nichrome), and steel. Materials useful for providing resistance or resistive heating are described in U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,093,894 to Deevi et al., U.S. Pat. No. 5,224,498 to Deevi et al., U.S. Pat. No. 5,224,498 to Sprinkel et al., the entire disclosures of which are incorporated herein by reference. No. 5,322,075 to Deevi et al., No. 5,353,813 to Deevi et al., No. 5,468,936 to Deevi et al., No. 5,498,850 to Das, No. 5,659,656 to Das, No. 5,498,855 to Deevi et al., No. 5,530,225 to Hajaligol, No. 5,665,262 to Hajaligol, No. 5,573,692 to Das et al., and No. 5,591,368 to Fleischhauer et al.

[0120] The heat source 306 can be provided in various forms, such as in the form of a foil, foam, disk, spiral, fiber, wire, film, thread, strip, ribbon, or cylinder. In some embodiments, the heat source 306 according to the present disclosure is a conductive substrate as described in U.S. Patent Application Publication No. 2013 / 0255702 to Griffith et al., the entire disclosure of which is incorporated herein by reference. As particularly shown in FIG. 3B, the heat source 306 includes a heating element, such as, for example, a cylindrical rod configured to generate heat in response to electrical power received from the power source 302. In this example, where the heat source 302 is a lithium ion battery, the cylindrical rod is electrically connected to the lithium ion battery to provide electrical power to the cylindrical rod. Such electrical connection is formed from a hardwired connection (not shown).

[0121] In some aspects, the heat source 306 is housed within a tubular casing 308 having opposing first and second ends. The tubular casing 308 defines an axis extending between the opposing first and second ends and is designed to have a similar shape and / or cross-section as the tubular control enclosure 304. For example, if the tubular control enclosure 304 has a cylindrical shape, then the tubular casing 308 has a cylindrical shape. However, the tubular casing 308 and the tubular control enclosure 304 also define different shapes in alternative embodiments.

[0122] The tubular casing 308 is configured to include an insulating material. For example, the insulating material of the tubular casing 308 includes graphite, graphene, and the like, to regulate the conduction of heat generated by the heat source 306. In particular, the anisotropic heat conducting properties of graphite, graphene, and the like are desirable for regulating the conduction of heat generated by the heat source 306. Thus, by housing the heat source 306 within a tubular casing 308 that includes one of these materials, the heat generated by the heat source 306 is regulated by the tubular casing 308 such that the exterior surface of the smoking article 300 is not exposed to high levels of heat during use.

[0123] In some embodiments, the first end of the tubular casing 308 is configured to be engaged to the second end of the power source 302 via the second end of the tubular control enclosure 304. For example, an engagement mechanism such as a threaded engagement, a packing material, a press-fit engagement, or the like is used to engage the second end of the tubular control enclosure 304 with the first end of the tubular casing 308. Thus, the second end of the power source 302 contained within the tubular control enclosure 304 and the first end of the heat source 306 contained within the tubular casing 308 are in communication with one another.

[0124] In some embodiments, the solid tobacco material 310 is also contained within the tubular casing 308. In some instances, the solid tobacco material 310 is configured as a cylindrical tube extending around the circumference of the axially extending heat source 306 between the heat source 306 and the tubular casing 308. For example, as shown specifically in FIG. 3B, the solid tobacco material 310 is distributed around the circumference of the axially extending heat source 306 with a substantially uniform thickness around the circumference of the heat source 306. Such a configuration is beneficial because it allows the heat source 306 to be positioned in intimate contact or proximity with the solid tobacco material 310 to generate an aerosol in response to heat generated by the heat source 306.

[0125] The solid tobacco material 310, in some examples, includes tobacco-containing beads, shredded tobacco, tobacco strips, reconstituted tobacco material pieces, or combinations thereof. The solid tobacco material 310 is formed as an extruded annular cylinder that is received on the circumferential surface of the axially extending heat source 306 within the tubular casing 308. Otherwise, the solid tobacco material 310 is packed, dropped, poured, or otherwise disposed between the inner circumferential surface of the tubular casing 308 and the circumferential surface of the axially extending heat source 306. The solid tobacco material 310, in some embodiments, is a "dry" tobacco material such that the tobacco material is not combined with an aerosol precursor composition when distributed around the circumferential surface of the axially extending heat source 306. However, in other embodiments, the solid tobacco material 310 is combined with an aerosol precursor composition, such as those described in connection with the smoking article 200.

[0126] 3B, the mouthpiece 312 is defined by the second end of the tubular casing 310 and is configured to receive aerosol from the solid tobacco material 310 in response to a draw applied to the mouthpiece 312. Thus, the tubular casing 310 extends axially around the heat source 306 from a first end engaged to the second end of the power source 302 to a second end defining the mouthpiece 312. The mouthpiece 312 is, in some embodiments, an integral component of the tubular casing 310 and defines an orifice through which the generated aerosol is drawn and received by the user. Otherwise, the mouthpiece 312 is a separate component. As shown in FIGS. 3A and 3B, when the smoking article 300 is provided in an assembled state, the mouthpiece 312 is provided opposite the cylindrical tube of the solid tobacco material 310 from the power source 302.

[0127] In some further embodiments, a filter material 314 is provided with the smoking article 300. More specifically, for example, the filter material 314 extends at least partially around the circumference of the cylindrical tube of solid tobacco material 310 and around the second end of the tubular casing 308 within the mouthpiece 312. Due to the insulating properties of the tubular casing 308, the filter material 314 is not exposed to high levels of heat, which is desirable for a pleasant smoking or smoking-like experience for a user of the smoking article 300. In any event, in some embodiments, the filter material 314 comprises cellulose acetate or another similar material.

[0128] The smoking article 300 further includes a control unit 316 in communication with the power source 302. The control unit 316 is in some embodiments housed within the tubular control enclosure 304, although the control unit 316 is alternatively housed within the tubular casing 302 or within a separate control enclosure (not shown).

[0129] The control unit 316 is configured to perform various functions including, for example, activating the power generated by the power source 302 and directing power to the heat source 306. Thus, the control unit 316 can regulate the heat generated by the heat source 306 by the control unit. The heating is characterized in relation to the amount of aerosol generated. Specifically, the smoking article 300 is configured to provide the amount of heat required to generate a defined volume of aerosol (e.g., about 0.5 ml to about 100 ml, or any other volume deemed useful for a smoking article, as described elsewhere herein). In some cases, the amount of heat generated is measured for a 2 second puff that provides about 35 ml of aerosol at a heater temperature of about 290°C. In some embodiments, the article 300 provides heat, preferably, from about 1 to about 50 Joules per second (J / s), from about 2 J / s to about 40 J / s, from about 3 J / s to about 35 J / s, or from about 5 J / s to about 30 J / s. Otherwise, the amount of heat produced is measured relative to the total puff provided. In some cases, the amount of heat produced by article 300 preferably provides from about 15 puffs to about 20 puffs. In any case, the aerosol produced is limited to only what is necessary so that excess power is not unnecessarily consumed.

[0130] Other functions of the control unit 316 include, for example, controlling power discharge in response to a stimulus, controlling and / or monitoring the flow of electrical energy, etc. Specifically, in some embodiments, the control unit 316 can control the flow of electrical energy from the power source 302 to other elements of the article 300, such as the heat source 306. Specifically, in some embodiments, the control unit 316 activates the flow of electrical current from the power source 302 to the heat source 306. According to some embodiments of the present disclosure, the smoking article 300 includes an actuation mechanism, such as a push button 318, in communication with (e.g., linked to) the control unit 316 and configured to control the actuation of electrical power generated by the power source 302. In this manner, the push button 318 located on the tubular control enclosure 304 or elsewhere is configured to manually control the flow of electrical current, and a consumer operates the push button 318 to turn on the article 300 and / or activate the flow of electrical current to the power source 302. In some embodiments, one or more, two or more, three or more, etc., actuation mechanisms are provided for manual ability to power article 300 on and off, and for actuation such as the flow of power generated by power source 302, e.g., current from a battery.

[0131] Instead of (or in addition to) the push button 318, in some embodiments, the smoking article 300 includes one or more controls (i.e., puff-activated heating) (not shown) that are responsive to a consumer's drawing on the article 300. For example, the article 300 includes a switch (i.e., a puff-activated switch) that is sensitive to either pressure changes or airflow changes as the consumer draws on the article. Other suitable current activation / deactivation mechanisms include, for example, a temperature-activated on / off switch or a lip-pressure-activated switch. An exemplary mechanism for providing puff-activation capability includes the Model 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc., Freeport, Illinois. With such a sensor, the heat source 306 is rapidly activated by pressure changes as the consumer draws on the mouthpiece 318 of the article 300. Additionally, flow-sensing devices, such as those using the principles of hot wire anemometry, are suitable for sufficiently rapid energization of the heat source 306 after sensing a change in airflow. Another suitable purge-activated switch is a pressure differential switch, such as model number MPL-502-V, range A, manufactured by Micro Pneumatic Logic, Inc., Fort Lauderdale, Fla. Another suitable purge-activated mechanism is a pressure-sensitive transducer (e.g., with an amplifier or gain stage) coupled in turn to a comparator for detecting a predetermined threshold pressure change. Yet another suitable purge-activated mechanism is a vane deflected by airflow, the movement of which is detected by a motion-sensing arrangement. Yet another suitable activation mechanism is a piezoelectric switch. Yet another suitable switch is a suitably connected Honeywell MicroSwitch Microbridge Airflow Sensor, part number AWM 2100V, manufactured by the MicroSwitch division of Honeywell, Inc., Freeport, Ill. Additional examples of demand-operated electrical switches suitable for heating circuits according to the present disclosure are described in U.S. Pat. No. 4,735,217 to Gerth et al., which is incorporated herein by reference in its entirety. Other suitable differential switches, analog pressure sensors, flow sensors, etc. will be apparent to those of ordinary skill in the art with the knowledge of this disclosure.A pressure sensing tube or other passageway providing a fluid connection between the puff-actuated switch and the airflow passageway in the smoking article 300 is suitable so that pressure changes during a puff are easily identified by the switch. Additional descriptions of current regulating circuits and other control units, including microcontrollers suitable for the present smoking articles, are provided in U.S. Patent Nos. 4,922,901, 4,947,874 and 4,947,875 to Brooks et al., 5,372,148 to McCafferty et al., 6,040,560 to Fleischhauer et al., and 7,040,314 to Nguyen et al., all of which are incorporated herein by reference in their entireties.

[0132] Furthermore, in some examples, capacitive sensing elements are incorporated into the smoking article 300 in various ways to enable various types of "power-up" and / or "power-down" for one or more elements of the smoking article 300. Capacitive sensing includes the use of any sensor incorporating technology based on capacitive coupling, such as, but not limited to, sensors that detect and / or measure proximity, position or displacement, humidity, fluid level, pressure or acceleration. Capacitive sensing results from electronic elements that provide surface capacitance, projected capacitance, mutual capacitance or self-capacitance. Capacitive sensors generally detect anything that is conductive or has a dielectric constant different from air. Capacitive sensors, for example, replace mechanical buttons (i.e., the push button 318 referenced above) with capacitive alternatives. Thus, one particular application of capacitive sensing according to the present disclosure is a touch-capacitive sensor. For example, there is a touchable portion (i.e., a touchpad) on the smoking article 300 that allows the user to input various commands. At its most basic, the touch pad provides power to the heat source 306 in much the same manner as the push button 318, as already described above. In other embodiments, capacitive sensing is applied near the mouthpiece 312 of the smoking article 300 such that the presence and / or pressure of the lips on the smoking article 300, or drawing on the article, signals the smoking article 300 to provide power to the heat source 306. In accordance with the present disclosure, in addition to touch capacitance sensors, motion capacitance sensors, liquid capacitance sensors and accelerometers are suitable for eliciting various responses from the smoking article 300. Additionally, photoelectric sensors are also suitable for use in the smoking article 300.

[0133] The sensor utilized in the smoking article 300 is configured to explicitly signal the flow of power to the heat source 306 to heat the solid tobacco material 310 and form an aerosol for inhalation by the user. The sensor may also provide additional functionality. For example, a "wake-up" sensor is suitable for inclusion in the smoking article 300. Other sensing methods that provide similar functionality may also be utilized in accordance with the present disclosure.

[0134] The control unit 316 further includes current regulation circuitry (not shown), which in some embodiments is specifically time-based. Specifically, such circuitry includes a mechanism for allowing the flow of current through the heat source 306 to remain uninterrupted for an initial period during a draw, and a timer device that subsequently regulates the current flow until the draw is completed. For example, subsequent regulation may include rapid on-off switching (e.g., on the order of about every 1-50 milliseconds) of the current flow from the power source 302 to maintain the heat source 306 within a desired temperature range. Additionally, regulation may include simply allowing the current flow to remain uninterrupted until the desired temperature is achieved, and then turning off the current flow entirely. The heat source 306 is reactivated by the consumer initiating another puff on the mouthpiece 312 on the article 300 (or by manually activating the push button 318, depending on the particular switch embodiment used to activate the heat source).

[0135] Alternatively, the subsequent adjustment includes modulating the flow of current through the heat source 306 to maintain the heat source 306 within a desired temperature range. In some embodiments, to emit a desired amount of the aerosol described above, the heat source 306 is energized for a duration of about 0.2 seconds to about 5.0 seconds, about 0.3 seconds to about 4.5 seconds, about 0.5 seconds to about 4.0 seconds, about 0.5 seconds to about 3.5 seconds, or about 0.6 seconds to about 3.0 seconds. One exemplary time-based current adjustment circuit includes a transistor, a timer, a comparator, and a capacitor. Suitable transistors, timers, comparators, and capacitors are commercially available and will be apparent to one of ordinary skill in the art. An exemplary timer is the so-called "555 timer" available from NEC Electronics as C-1555C and from General Electric Intersil, Inc. as ICM7555, as well as various other sizes and configurations. An exemplary comparator is available from National Semiconductor as LM311. Further description of such time based current regulation circuits and other control units useful in the smoking article 300 is provided in U.S. Pat. Nos. 4,922,901, 4,947,874 and 4,947,875, all to Brooks et al., all of which are incorporated herein by reference in their entireties.

[0136] The control unit 316 can be configured, among other things, to closely control the amount of heat provided by the power source 302 to the heat source 306. In some embodiments, the current regulation component can stop the flow of current to the heat source 306 when a defined temperature is achieved. Such defined temperature is in a range substantially high enough to aerosolize any solid tobacco material 310 and any additional inhalable substances, as described elsewhere herein, and to provide an amount of aerosol equivalent to a typical puff of a conventional cigarette. The heat required to aerosolize a volume of the solid tobacco material 310 sufficient to provide the desired volume for a single puff is variable, but heating to a temperature of about 120°C or higher, about 130°C or higher, about 140°C or higher, or about 160°C or higher is particularly useful for the heat source 306. In some embodiments, the heating temperature is about 180°C or higher, about 200°C or higher, about 300°C or higher, or about 350°C or higher to aerosolize an appropriate amount of the solid tobacco material 310. In additional embodiments, the specified temperature for aerosol formation is from about 120°C to about 350°C, from about 140°C to about 300°C, or from about 150°C to about 250°C.

[0137] In yet another embodiment, the control unit 316 including the current regulation component is configured to cycle the current from the power source 302 to the heat source 306 off and on to maintain a first temperature that is lower than the aerosol-forming temperature, and then increase the current flow to achieve a second temperature that is higher than the first temperature and is the aerosol-forming temperature. Such control advantageously improves the response time of the article 300 to aerosol formation, such that aerosol formation begins almost instantly upon initiation of a puff by the consumer. According to some embodiments, the first temperature (e.g., characterized as a standby temperature) is only slightly lower than the aerosol-forming temperature defined above. Specifically, for example, the standby temperature is about 50°C to about 150°C, about 70°C to about 140°C, about 80°C to about 120°C, or about 90°C to about 110°C.

[0138] Many modifications and other embodiments of the present disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the present disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A smoking article, a power supply having opposed first and second ends defining an axis extending through the power supply; a heat source in communication with the second end of the power source and extending along the axis, the heat source configured to generate heat in response to receiving power from the power source; a tubular casing having a first end engaged with the second end of the power source and extending axially around the heat source to the second end; a solid tobacco material contained within a tubular casing, the solid tobacco material configured as a cylindrical tube extending around a circumference of an axially extending heat source between the heat source and the tubular casing, the solid tobacco material configured to generate an aerosol in response to heat generated by the heat source; a mouthpiece defined by a second end of the tubular casing facing the cylindrical tube of solid tobacco material from the power source, the mouthpiece configured to receive an aerosol from the solid tobacco material in response to drawing applied to the mouthpiece; a filter material extending at least partially around a circumference of the cylindrical tube of solid tobacco material and around the second end of the tubular casing within the mouthpiece; Smoking articles, including:

2. 2. The smoking article of claim 1, wherein the filter material comprises cellulose acetate.

3. 2. The smoking article of claim 1, wherein the power source comprises a lithium ion battery.

4. 4. The smoking article of claim 3, wherein the heat source is a cylindrical rod electrically connected to a lithium ion battery.

5. 2. A smoking article according to claim 1, wherein the power source is housed in a tubular control enclosure having opposed first and second ends, the second end of the tubular control enclosure being engaged with the first end of the tubular casing.

6. 6. A smoking article according to claim 5, further comprising a control unit in communication with the power source, the control unit configured to operate electrical power generated by the power source and direct electrical power to the heat source.

7. 7. A smoking article according to claim 6, further comprising a push button in communication with the control unit, the push button configured to control operation of electrical power generated by the power source.

8. 2. The smoking article of claim 1, wherein the tubular casing comprises a thermal insulating material.

9. 9. A smoking article according to claim 8, wherein the insulating material comprises graphite or graphene.

10. 10. The smoking article of claim 1, wherein the solid tobacco material comprises tobacco-containing beads, shredded tobacco, strips of tobacco, pieces of reconstituted tobacco material, or combinations thereof.

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