Aerosol delivery device having a separable heat source and substrate

Abstract

The present disclosure relates to an aerosol delivery device. In some embodiments, the aerosol delivery device may include a holder, a thermal portion including a heat source configured to generate heat, and a substrate portion including a substrate material including an aerosol precursor composition. The holder may be configured to receive the thermal portion and the substrate portion, and the thermal portion and the substrate portion may be disposed adjacent to each other, and the thermal portion and the substrate portion may be separate components configured to be independently removable and replaceable within the holder.

Description

Technical Field

[0001] This application claims the priority and benefit of U.S. Patent Application No. 16 / 516,932, filed on Jul. 19, 2019, entitled “Aerosol Delivery Device with Separable Heat Source and Substrate,” which is incorporated herein by reference in its entirety.

[0002] 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 heat source, such as a combustible carbonaceous ignition source, for the generation of an aerosol (e.g., a smoking article for obtaining components of tobacco, tobacco extracts, nicotine, synthetic nicotine, non-nicotine flavorants, and other materials in an inhalable form, commonly referred to as a heated system or an e-cigarette). The components of such articles can be made from or derived from tobacco, or these articles can be characterized by incorporating tobacco in other ways for human consumption, and can vaporize components of tobacco and / or other tobacco-related materials to form an inhalable aerosol for human consumption.

Background Art

[0003] Over the years, many smoking articles have been proposed as improved or alternative smoking products based on the combustion of tobacco. Exemplary alternatives include devices in which a solid fuel or a liquid fuel is burned to transfer heat to the tobacco, or devices in which a chemical reaction is used to provide such a heat source. Examples include the smoking articles described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference.

[0004] The gist of improved or alternative smoking articles has typically been to provide the sensations associated with smoking a cigarette, cigar or pipe without delivering significant amounts of incomplete combustion and pyrolysis products. For this purpose, many smoking products, aroma generators and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat a volatile material or to provide the smoking sensation of a cigarette, cigar or pipe without significantly burning the tobacco. See, for example, the various alternative smoking articles, aerosol delivery devices and heat sources described in the background art of Robinson et al. U.S. Patent No. 7,726,320, Griffith, Jr. et al. U.S. Patent Application Publication No. 2013 / 0255702 and Sears et al. U.S. Patent Application Publication No. 2014 / 0096781, which are incorporated herein by reference. Also see, for example, the various types of smoking articles, aerosol delivery devices and electrical heat sources referred to by trademark name and commercial suppliers described in Bless et al. U.S. Patent Application Publication No. 2015 / 0220232, which is incorporated herein by reference. Additional types of smoking articles, aerosol delivery devices and electrical heat sources referred to by trademark name and commercial suppliers are also described in DePiano et al. U.S. Patent Application Publication No. 2015 / 0245659, which is incorporated herein by reference in its entirety.Other representative cigarette or smoking articles that are described and in some cases commercially available include those described in U.S. Patent No. 4,735,217 to Gerth, U.S. Patent No. 4,922,901 to Brooks, U.S. Patent No. 4,947,874, U.S. Patent No. 4,947,875, U.S. Patent No. 5,060,671 to Counts, U.S. Patent No. 5,249,586 to Morgan, U.S. Patent No. 5,388,594 to Counts, U.S. Patent No. 5,666,977 to Higgins, U.S. Patent No. 6,053,176 to Adams, U.S. Patent No. 6,164,287 to White, U.S. Patent No. 6,196,218 to Voges, U.S. Patent No. 6,810,883 to Felter, U.S. Patent No. 6,854,461 to Nichols, U.S. Patent No. 7,832,410 to Hon, U.S. Patent No. 7,513,253 to Kobayashi, U.S. Patent No. 7,726,320 to Robinson, U.S. Patent No. 7,896,006 to Hamano, U.S. Patent No. 6,772,756 to Shayan, U.S. Patent Application Publication No. 2009 / 0095311 to Hon, U.S. Patent Application Publication No. 2006 / 0196518 to Hon, U.S. Patent Application Publication No. 2009 / 0126745, U.S. Patent Application Publication No. 2009 / 0188490, U.S. Patent Application Publication No. 2009 / 0272379 to Thorens, U.S. Patent Application Publication No. 2009 / 0260641, U.S. Patent Application Publication No. 2009 / 0260642 to Monsees, U.S. Patent Application Publication No. 2008 / 0149118, U.S. Patent Application Publication No. 2010 / 0024834 to Oglesby, U.S. Patent Application Publication No. 2010 / 0307518 to Wang, and International Publication No. 2010 / 091593 to Hon, which are incorporated herein by reference.

[0005] A variety of styles and methods for assembling smoking articles having a plurality of sequentially arranged segmented components have been proposed. See, for example, the various types of assembly techniques and methods described in U.S. Patent No. 5,469,871 to Barnes et al., U.S. Patent No. 7,647,932 to Crooks et al., and U.S. Patent Application Publication No. 2010 / 0186757 to Crooks et al., U.S. Patent Application Publication No. 2012 / 0042885 to Stone et al., and U.S. Patent Application Publication No. 2012 / 00673620 to Conner et al., each of which is incorporated herein by reference in its entirety.

[0006] Certain types of rolled tobacco using a carbonaceous fuel element are commercially available from R.J. Reynolds Tobacco Company under the trade names "Premier", "Eclipse", and "Revo". See, for example, the types of rolled tobacco described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R.J. Reynolds Tobacco Company Monograph (1988) and Inhalation Toxicology, 12:5, pages 1-58 (2000). Further, in Japan, a similar type of rolled tobacco is sold by Japan Tobacco Inc. under the product name "Steam Hot One".

[0007] In some cases, some smoking articles, particularly those using conventional cigarette paper materials, tend to burn the cigarette paper material covering the ignitable fuel source due to the high temperatures achieved by a fuel source in proximity to the cigarette paper material. This can potentially reduce the enjoyment of the smoking experience for some consumers and may mask or undesirably alter the flavors delivered to the consumer by the aerosol delivery components of the smoking article. In further examples, conventional smoking articles may produce relatively significant levels of gases such as carbon monoxide and / or carbon dioxide (e.g., as products of carbon combustion) during use. In yet another example, conventional smoking articles may be affected by insufficient performance with respect to aerosolizing aerosol-forming components.

Prior Art Documents

Patent Documents

[0008]

Patent Document 1

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Non-Patent Document

[0009]

Non-Patent Document 1

Non-Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0010] Accordingly, it may be desirable to provide a smoking article that addresses one or more of the technical problems sometimes associated with conventional smoking articles. Further, it may be desirable to provide a smoking article that is easy to use and has reusable components.

Means for Solving the Problems

[0011] The present disclosure relates to an aerosol delivery device and a cartridge for use with the aerosol delivery device. The present disclosure includes, without limitation, the following exemplary embodiments.

[0012] Exemplary Embodiment 1: An aerosol delivery device comprising a holder, a heat portion comprising a heat source configured to generate heat, and a substrate portion comprising a substrate material comprising an aerosol precursor composition, wherein the holder is configured to receive the heat portion and the substrate portion, the heat portion and the substrate portion are disposed in proximity to each other, the heat portion and the substrate portion are separate components, and the heat portion and the substrate portion are configured to be removably and interchangeably independent within the holder.

[0013] Exemplary Embodiment 2: The aerosol delivery device of any of the preceding exemplary embodiments, or the aerosol delivery device of any combination of any of the preceding exemplary embodiments, wherein the heat portion and the substrate portion are disposed in an end-to-end configuration.

[0014] Exemplary Embodiment 3: The aerosol delivery device of any of the preceding exemplary embodiments, or the aerosol delivery device of any combination of any of the preceding exemplary embodiments, wherein the heat portion and the substrate portion are disposed in an adjacent configuration.

[0015] Exemplary Embodiment 4: The aerosol delivery device of any of the preceding exemplary embodiments, or the aerosol delivery device of any combination of any of the preceding exemplary embodiments, wherein the longitudinal axis of the heat portion has an offset angle with respect to the longitudinal axis of the substrate portion.

[0016] Exemplary Embodiment 5: An aerosol delivery device of any of the foregoing exemplary embodiments, or an aerosol delivery device of any combination of any of the foregoing exemplary embodiments, in which the heat portion and the substrate portion are arranged in an over-under arrangement.

[0017] Exemplary Embodiment 6: An aerosol delivery device of any of the foregoing exemplary embodiments, or an aerosol delivery device of any combination of any of the foregoing exemplary embodiments, in which the heat portion and the substrate portion are in contact with each other.

[0018] Exemplary Embodiment 7: An aerosol delivery device of any of the foregoing exemplary embodiments, or an aerosol delivery device of any combination of any of the foregoing exemplary embodiments, in which there is a space between the heat portion and the substrate portion.

[0019] Exemplary Embodiment 8: An aerosol delivery device of any of the foregoing exemplary embodiments, or an aerosol delivery device of any combination of any of the foregoing exemplary embodiments, further including a heat transfer component disposed between the heat portion and the substrate portion.

[0020] Exemplary Embodiment 9: An aerosol delivery device of any of the foregoing exemplary embodiments, or an aerosol delivery device of any combination of any of the foregoing exemplary embodiments, in which the heat transfer component is configured to be removably and replaceably independent within a holder.

[0021] Exemplary Embodiment 10: An aerosol delivery device of any of the foregoing exemplary embodiments, or an aerosol delivery device of any combination of any of the foregoing exemplary embodiments, in which the heat transfer component is integral with one or more of the heat portion or the substrate portion.

[0022] Exemplary Embodiment 11: An aerosol delivery device of any of the foregoing exemplary embodiments, or an aerosol delivery device of any combination of any of the foregoing exemplary embodiments, in which the substrate portion includes an outer housing surrounding at least a portion of the substrate material.

[0023] Exemplary Embodiment 12: The thermal portion includes an outer housing that surrounds at least a portion of the heat source, an aerosol delivery device of any of the foregoing exemplary embodiments, or an aerosol delivery device of any combination of any of the foregoing exemplary embodiments.

[0024] Exemplary Embodiment 13: The holder includes a thermal portion compartment, an aerosol delivery device of any of the foregoing exemplary embodiments, or an aerosol delivery device of any combination of any of the foregoing exemplary embodiments.

[0025] Exemplary Embodiment 14: The holder includes a substrate portion compartment, an aerosol delivery device of any of the foregoing exemplary embodiments, or an aerosol delivery device of any combination of any of the foregoing exemplary embodiments.

[0026] Exemplary Embodiment 15: The holder includes a thermal portion compartment and a separate substrate portion compartment, an aerosol delivery device of any of the foregoing exemplary embodiments, or an aerosol delivery device of any combination of any of the foregoing exemplary embodiments.

[0027] These and other features, aspects, and advantages of the present disclosure will become apparent from the following detailed description, read in conjunction with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four, or more of the above-described embodiments, as well as any combination of any two, three, four, or more features or elements described in the present disclosure, regardless of whether such features or elements are explicitly combined in the description of a particular embodiment herein. The present disclosure is intended to be read as a whole so that, in any of its various aspects and embodiments, any separable feature or element of the disclosed invention appears to be combinable as intended, unless the context clearly indicates otherwise.

[0028] The present disclosure has been described in the foregoing general terms and reference will now be made to the accompanying drawings, which are not necessarily drawn to scale.

Brief Description of the Drawings

[0029]

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DETAILED DESCRIPTION OF THE INVENTION

[0030] The present disclosure will be described in more detail below with reference to its exemplary embodiments. These exemplary embodiments are described so that the present disclosure is thorough and complete and conveys the full scope of the present disclosure to those skilled in the art. In fact, the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will satisfy the applicable legal requirements. The singular forms "a", "an", and "the" as used in this specification and the appended claims include plural referents unless the context clearly dictates otherwise.

[0031] The present disclosure provides an article (and its assembly and / or manufacture) in which a material is heated (preferably without significantly burning the material) to form an aerosol and / or an inhalable substance. Such an article is most preferably small enough to be considered a "portable" device. In a preferred embodiment, the article is characterized as a smoking article. As used herein, the term "smoking article" refers to an article and / or device that provides many of the sensations of smoking a cigarette, cigar, or pipe (e.g., form of inhalation and exhalation, type of taste or flavor, sensory stimulating effect, physical feel, form of use, visual stimulation as provided by a visible aerosol, etc.) without substantially burning any component of the article and / or device. As used herein, the term "smoking article" does not necessarily mean that during operation, the article or device produces smoke in the sense of an aerosol resulting from the combustion or pyrolysis of tobacco, but rather that the article or device produces a vapor (including vapor within an aerosol that may be considered to be visible and described as smoky) resulting from the volatilization or vaporization of certain components, elements, etc. of the article and / or device. In a preferred embodiment, the article or device characterized as a smoking article incorporates tobacco and / or tobacco-derived components.

[0032] As described above, the aerosol generation components of certain preferred aerosol delivery devices can provide various sensations (e.g., inhalation and exhalation patterns, types of taste or flavor, sensory stimulation effects, physical sensations, usage patterns, visual stimulation as provided by visible aerosols, etc.) associated with smoking a cigarette, cigar, or pipe that is used by igniting and burning tobacco (and thus, by inhaling tobacco smoke) without substantially burning any of its components. For example, a user of an aerosol delivery device according to some exemplary embodiments of the present disclosure can hold and use its components and inhale from one end of the component to inhale the aerosol generated by the component at selected time intervals, similar to how a smoker uses a conventional smoking article.

[0033] The articles or devices of the present disclosure are also characterized as being vapor generation articles, aerosol delivery articles, or drug delivery articles. Thus, such articles or devices can be configured to provide one or more substances in an inhalable form or state. For example, the inhalable substance can be substantially in the form of vapor (e.g., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance can be in the form of an aerosol (e.g., a suspension of fine solid particles or droplets in a gas). For clarity, the term "aerosol" as used herein means to include vapors, gases, and aerosols in a form or type suitable for human inhalation, regardless of whether they are visible or can be considered to be in a smoky form. In some embodiments, the terms "vapor" and "aerosol" may be used interchangeably. Thus, for simplicity, the terms "vapor" and "aerosol" used to describe the present disclosure are understood to be interchangeable unless otherwise specified.

[0034] The smoking articles of the present disclosure, when in use, are subject to many of the physical actions of an individual when using conventional smoking articles (e.g., cigarettes, cigars or pipes that are used by being lit by a flame and subsequently inhaled by burning and / or combusting tobacco). For example, a user of the smoking article of the present disclosure holds the article as in a conventional smoking article, sucks on one end of the article to inhale the aerosol generated by the article, and smokes at selected time intervals.

[0035] The systems are generally described herein with respect to embodiments related to smoking articles such as so-called "tobacco heating products", but it should be understood that the mechanisms, components, features and methods may be embodied in many different forms and associated with a variety of articles. For example, the descriptions provided herein may be used in combination with embodiments of related packaging for conventional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heated cigarettes, and the products disclosed herein. Accordingly, it should be understood that the descriptions of the mechanisms, components, features and methods disclosed herein are discussed only as examples with respect to embodiments related to aerosol delivery devices and may be embodied and used in a variety of other products and methods.

[0036] The smoking articles of the present disclosure generally include a number of elements provided or housed within a certain housing such as a housing, an outer wrap or package, a casing, components, modules, members, etc. The overall design of the housing is variable, and the form or configuration of the housing that defines the overall size and shape of the smoking article is also variable. In some, but not all, embodiments, the overall design, size and / or shape of the housing is similar to that of a conventional cigarette or cigar wrapped in paper. Typically, a housing shaped like a cigarette or cigar wrapped in paper includes separable components, members, etc. that are engaged to form the housing. For example, in some aspects, such a smoking article may include separable components including a holder and a cartridge including an aerosol delivery component (e.g., a base material, etc.) and a heat source component. In various aspects, the heat source can generate heat to aerosolize a base material including, for example, an extrusion structure in the form of a solid or liquid (e.g., beads, sheets, shreds, wraps) and / or a base material combined with an aerosol precursor composition, tobacco and / or tobacco-related materials, e.g., materials naturally found in tobacco directly separated from tobacco, or synthetically prepared materials, etc. In some embodiments, the extrusion structure may comprise a tobacco product or a composite of tobacco and other materials, such as ceramic powder, etc. In other embodiments, a tobacco extract / slurry may be carried on porous ceramic beads. Other embodiments may use non-tobacco products. In some embodiments, porous beads / powders (ceramics) carrying an aerosol precursor composition may be used. In other embodiments, rods / cylinders made from an extrusion slurry of ceramic powder and an aerosol precursor composition may also be used.

[0037] According to certain aspects of the present disclosure, it can be advantageous to provide a smoking article that provides easy-to-use and reusable components. FIG. 1 shows a perspective view of such a smoking article according to one embodiment of the present disclosure. In particular, FIG. 1 shows a perspective view of a smoking article 100 that includes a removable cartridge 102 and a holder 104. The holder 104 includes a body portion 120 and a mouthpiece portion 122 disposed at the mouth end of the holder 104. In various embodiments of the holder, the structure and method for receiving the removable cartridge of the present disclosure can vary, but in the illustrated embodiment, the removable cartridge 102 is configured to be removably received longitudinally within a cavity 106 defined on the receiving end of the body portion 120 of the holder 104. Some examples of one or more holders that can be used with the removable cartridge of the present disclosure are described in U.S. Patent Application No. 16 / 035,103, filed July 13, 2018, entitled "Smoking Article with Detachable Cartridge," which is hereby incorporated by reference in its entirety.

[0038] In various embodiments, the heat portion and the substrate portion of the present disclosure can be used with various different holders. Some examples are holders that can be used with the present disclosure, each of which is incorporated herein by reference in its entirety: U.S. Patent Application No. 16 / 516,573, filed July 19, 2019, entitled "Holder for Aerosol Delivery Device with Detachable Cartridge"; U.S. Patent Application No. 16 / 516,601, filed July 19, 2019, entitled "Aerosol Delivery Device with Sliding Sleeve"; U.S. Patent Application No. 16 / 516,621, filed July 19, 2019, entitled "Aerosol Delivery Device with Clamshell Holder for Cartridge"; and U.S. Patent Application No. 16 / 516,821, filed July 19, entitled "Aerosol Delivery Device with Rotatable Enclosure for Cartridge".

[0039] Figure 2 shows a perspective view of the removable cartridge 102 of FIG. 1 according to an exemplary embodiment of the present disclosure. In the illustrated embodiment, the removable cartridge 102 includes a heat portion 108 including a heat source 109, a substrate portion 110 including a substrate material 116 (see FIG. 3), and an outer housing 112 configured to surround at least a portion of the heat source 109 and the substrate material 116. In the illustrated embodiment, the cartridge 102 and the holder 104 have an overall substantially cylindrical shape, but in various other embodiments, either or both of these components (and / or any of their sub-components, e.g., the body portion and / or the mouthpiece portion, the holder, and / or the heat source, the outer housing, and / or the substrate material of the cartridge) may have different shapes. It should be noted that, for example, in some embodiments, one or both of the holder or the cartridge (and / or any of their sub-components) may have a substantially rectangular shape, e.g., a substantially rectangular cuboid shape. In other embodiments, one or both of the holder or the cartridge (and / or any of their sub-components) may have other handheld shapes. For example, in some embodiments, the holder may have a small box shape, various pod mod shapes, or a fob shape. Some examples of cartridge configurations that may be applicable to the present disclosure can be found in U.S. Patent Application No. 16 / 515,637, filed on July 18, 2019, entitled "Aerosol Delivery Device with Consumable Cartridge", which is hereby incorporated by reference in its entirety.

[0040] In various embodiments, the heat source can be configured to generate heat upon its ignition. In the illustrated embodiment, the heat source 109 has a generally cylindrical shape and includes a combustible fuel element incorporating a combustible carbonaceous material. In other embodiments, the heat source may have a different shape, such as a prism shape having a cubic or hexagonal cross-section. The carbonaceous material generally has a high carbon content. Preferred carbonaceous materials are composed primarily of carbon and / or typically have a carbon content of greater than about 60 percent, generally greater than about 70 percent, often greater than about 80 percent, and frequently greater than about 90 percent on a dry weight basis.

[0041] In some cases, the heat source may incorporate elements other than the combustible carbonaceous material (e.g., tobacco components such as powdered tobacco or tobacco extracts; flavoring agents; salts such as sodium chloride, potassium chloride, and sodium carbonate; thermally stable graphite hollow cylindrical (e.g., tube) fibers; iron oxide powder; glass filaments; powdered calcium carbonate; alumina granules; ammonia sources such as ammonium salts; and / or binders such as guar gum, ammonium alginate, and sodium alginate). In other embodiments, the heat source may comprise a plurality of ignitable objects such as, for example, a plurality of ignitable beads. It should be noted that in other embodiments, the heat source may differ from the above in terms of composition or relative content. For example, in some embodiments, various forms of carbon such as graphite or graphene may be used as the heat source. In other embodiments, the heat source may have an increased level of activated carbon, carbon of various porosities, various amounts of carbon, blends of any of the above-described components, etc. In still other embodiments, the heat source may include a non-carbon heat source such as, for example, a combustible liquefied gas configured to generate heat upon its ignition. For example, in some embodiments, the liquefied gas may comprise one or more of petroleum gas (LPG or LP gas), propane, propylene, butylene, butane, isobutene, methylpropane, or n-butane. In still other embodiments, the heat source may comprise a heat source based on a chemical reaction, and the ignition of the heat source includes the interaction of two or more individual components. For example, a heat source based on a chemical reaction may include a metal agent and an activating solution, and the heat source is activated when the metal agent contacts the activating solution. Some examples of heat sources based on chemistry can be found in U.S. Patent No. 7,290,549 to Banerjee et al., which is hereby incorporated by reference in its entirety. Combinations of heat sources are also possible.

[0042] The specific dimensions of the applicable heat source can vary, but in the illustrated embodiment, the heat source 109 has a length in the inclusive range of about 5 mm to about 20 mm, and in some embodiments, it may be about 17 mm, and an overall diameter in the inclusive range of about 3 mm to about 8 mm, and in some embodiments, it may be about 4.8 mm (and in some embodiments, about 7 mm).

[0043] In other embodiments, the heat source may be constructed in various ways, but in the illustrated embodiment, the heat source 109 is extruded or compounded using a pulverized or powdered carbonaceous material and has a density of about 0.5 g / cm 3 sup, often about 0.7 g / cm 3 sup, frequently about 1 g / cm 3 sup. See, for example, the fuel source components, formulations, and types of 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 hereby incorporated by reference in their entirety.

[0044] In various embodiments, the heat source may have various forms including, for example, a generally solid cylindrical or hollow cylindrical (e.g., tubular) shape. However, the heat source 109 of the illustrated embodiment includes an extruded monolithic carbonaceous material having a generally cylindrical shape that includes a plurality of internal passages 114 extending longitudinally from a first end of the heat source 109 to an opposite second end of the heat source 109. In the illustrated embodiment, there are approximately 13 internal passages 114 with a single central internal passage 114a, 6 peripheral internal passages 114b spaced from the central internal passage 114a and having a similar size (e.g., diameter) as the central internal passage 114a, and 6 peripheral internal passages 114c spaced from the outer surface of the heat source 109 and having a diameter smaller than the diameter of the central internal passage 114a. It should be noted that in other embodiments, there need not be a plurality of internal passages and / or the plurality of internal passages can take other forms and / or sizes. For example, in some embodiments, there may be only two internal passages, and still other embodiments may include only one internal passage. Still other embodiments need not include any internal passages at all. Additional embodiments may include a plurality of internal passages that need not be equal in diameter and / or shape, may be unevenly spaced, and / or arranged within the heat source.

[0045] Although not shown in the figures, some embodiments may alternatively or additionally include one or more circumferential grooves that extend longitudinally from a first end of the heat source to a second end on the opposite side thereof. However, in other embodiments, the grooves need not extend over the entire length of the heat source. In some embodiments, such grooves may have substantially equal width and depth and may be distributed substantially equally around the circumference of the heat source. In such embodiments, there may be only two grooves, and still other embodiments may include only one groove. Still other embodiments may not include any grooves at all. Additional embodiments may include a plurality of grooves that may have unequal width and / or depth and may be unevenly spaced around the circumference of the heat source. In still other embodiments, the heat source may include flutes and / or slits that extend longitudinally from a first end of the extruded monolithic carbonaceous material to a second end on the opposite side thereof. In some embodiments, the heat source may comprise a foamed carbon monolith formed by a foaming process of the type disclosed in Lobovsky U.S. Patent No. 7,615,184, which is hereby incorporated by reference in its entirety. Accordingly, some embodiments may provide advantages with respect to reducing the time required to ignite the heat source. In some other embodiments, the heat source may be co-extruded with a layer of insulation (not shown), thereby reducing manufacturing time and cost. Other embodiments of the fuel element include carbon fibers of the type described in Brooks et al. U.S. Patent No. 4,922,901 or other heat source embodiments such as those disclosed in Takeuchi et al. U.S. Patent Application Publication No. 2009 / 0044818, each of which is hereby incorporated by reference in its entirety. Further examples of heat sources, methods, and smoking articles including such heat sources that include a debossing heat source system are disclosed in U.S. Patent Application No. 15 / 902,665, filed February 22, 2018, entitled "System for Debossing a Heat Generation Member, a Smoking Article Including the Debossed Heat Generation Member, and a Related Method", which is hereby incorporated by reference in its entirety.

[0046] Generally, the heat source is disposed sufficiently close to an aerosol delivery component (e.g., a substrate portion) having one or more aerosolizable components such that an aerosol (and any flavoring materials, medicaments, etc. similarly provided for delivery to the user) formed / volatilized by the application of heat from the heat source to the aerosolizable components is deliverable to the user via a mouthpiece. That is, when the heat source heats the substrate component, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the foregoing terms are rewordable such that references to release, releasing, releases, or released 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, an aerosol, or a mixture thereof. Further, considering commercial e-cigarettes such as the representative products listed in the background art section of the present disclosure, the selection of the various cigarette elements is understood.

[0047] Figure 3 shows a longitudinal cross-sectional view of the cartridge 102 of FIG. 1. As shown in the figure, the base material 116 of the illustrated embodiment has first and second ends on opposite sides of each other, and the heat source 109 is disposed adjacent to the first end of the base material 116. The dimensions of the various components of the cartridge may vary according to the requirements of a particular application, but in the illustrated embodiment, the cartridge 102 may have an overall length in the inclusive range of about 10 mm to about 50 mm, and a diameter in the inclusive range of about 2 mm to about 20 mm. Additionally, in the illustrated embodiment, the housing 112 may have a thickness in the inclusive range of about 0.05 mm to 0.5 mm. Further, in the illustrated embodiment, the base material 116 may have a length in the inclusive range of about 5 mm to 50 mm and a diameter slightly smaller than the diameter of the entire cartridge, for example, a diameter in the inclusive range of about 2.9 mm to about 9.9 mm, in order to correspond to the thickness of the housing 112.

[0048] In the illustrated embodiment, the base portion 110 comprises a base material 116 having a single segment, but in other embodiments, the base portion may include one or more additional base material segments. For example, in some embodiments, the smoking article 100 may further comprise a second base material segment (not shown) having first and second ends on opposite sides of each other. In various embodiments, one or more of the base materials may include tobacco or tobacco-related materials together with an aerosol precursor composition bound thereto. In other embodiments, a non-tobacco material such as a cellulose pulp material may be used. In other embodiments, the non-tobacco base material may not be a plant-derived material. Other possible compositions, components and / or additives for use with a single base material (and / or plural base materials) are described in more detail below. It should be noted that the following description should be applicable to any base material that can be used in the smoking articles described herein (e.g., the base material 116 of the illustrated embodiment).

[0049] Referring also to FIG. 1, ignition of the heat source 109 of the illustrated embodiment results in aerosolization of the aerosol precursor composition coupled to the substrate material 116. In various embodiments, the mouthpiece portion 122 is configured to receive the generated aerosol therethrough in response to suction applied to the mouthpiece portion 122 by the user. In some embodiments, the mouthpiece portion 122 may include a filter, and the filter is configured to receive the aerosol therethrough in response to suction applied to the mouthpiece portion 122. In various embodiments, the filter may be provided as a circular disk disposed radially and / or longitudinally proximate an end of the holder, facing the receiving end, in some aspects. Thus, upon suction of the mouthpiece portion 122, the filter may receive the aerosol flowing through the holder 104 of the smoking article 100. In some embodiments, the filter may include individual segments. For example, some embodiments may include a segment providing filtration, a segment providing draw resistance, a hollow segment providing space for the aerosol to cool, other filter segments, and any one or any combination of the foregoing. In some embodiments, the filter may also provide flavorant additives. In some embodiments, the filter may include one or more filter segments that may be replaceable. For example, in some embodiments, one or more filter segments, including filter segments providing different draw resistances and / or different flavors, may be replaceable to customize the user experience using the device.Some examples of flavorant materials and / or components configured to add flavor materials can be found in U.S. Patent Application No. 16 / 408,942, filed on May 10, 2019, entitled "Flavor Article for an Aerosol Delivery Device", U.S. Patent Application No. 15 / 935,105, filed on March 26, 2018, entitled "Aerosol Delivery Device Providing Flavor Control", and U.S. Patent Application No. 16 / 353,556, filed on March 14, 2019, entitled "Aerosol Delivery Device Providing Flavor Control", each of which is incorporated herein by reference in its entirety.

[0050] Preferably, the elements of the base material do not significantly thermally decompose (e.g., carbonize, char, or burn), and the aerosolized components are incorporated into the air drawn into the user's mouth through the smoking article, including the filter (if present). In the smoking article 100 of the illustrated embodiment, the base material 116 comprises a plurality of tobacco beads formed together in a generally cylindrical portion. However, in various embodiments, the base material may comprise a variety of different compositions and combinations thereof, as will be described in more detail below.

[0051] In one embodiment, for example, the base material may include a blend of flavorful aromatic tobacco in cut filler form. In another embodiment, the base material may include a reconstituted tobacco material as described in U.S. Patent No. 4,807,809 to Pryor et al., U.S. Patent No. 4,889,143 to Pryor et al., and U.S. Patent No. 5,025,814 to Raker, the entire disclosures of which are incorporated herein by reference. Further, the reconstituted tobacco material may include a reconstituted tobacco paper for a cigarette of the type described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R.J. Reynolds Tobacco Company Monograph (1988), the entire contents of which are incorporated herein by reference. For example, the reconstituted tobacco material may include a sheet-like material containing tobacco and / or tobacco-related materials. Thus, in some embodiments, the base material may be formed from a rolled roll of reconstituted tobacco material. In another embodiment, the base material may be formed from shredded pieces, flakes, etc. of the reconstituted tobacco material. In another embodiment, the tobacco sheet may include a superimposed layer (e.g., a gather web) that may or may not include a heat conductive component. An example of a base portion including a series of superimposed layers (e.g., a gather web) of an initial base sheet formed by a fibrous filler material, an aerosol-forming material, and a plurality of heat conductive components is described in U.S. Patent Application No. 15 / 905,320, filed February 26, 2018, entitled "Heat Conducting Substrate For Electrically Heated Aerosol Delivery Device", the entire disclosure of which is incorporated herein by reference.

[0052] In some embodiments, the base material may contain a plurality of microcapsules, beads, granules, etc. having tobacco-related materials. For example, a typical microcapsule may have a substantially spherical shape and may have an outer cover or shell containing a liquid core region such as a tobacco-derived extract. In some embodiments, one or more of the base materials may contain a plurality of microcapsules each formed in a hollow cylindrical shape. In some embodiments, one or more of the base materials may contain a binder material configured to maintain the structural shape and / or integrity of a plurality of microcapsules formed in a hollow cylindrical shape.

[0053] The tobacco used in one or more of the base materials may include tobacco such as flue-cured tobacco, burley tobacco, oriental tobacco, Maryland tobacco, dark tobacco, dark air-cured tobacco, and rustic tobacco, as well as other rare or specialty tobaccos, or blends thereof, or may be derived therefrom. Various representative types of tobacco, types of tobacco processing, and types of tobacco blends 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. 6,701,936 to Shafer et al., U.S. Patent No. 6,730,832 to Dominguez et al., U.S. Patent No. 7,011,096 to Li et al., U.S. Patent No. 7,017,585 to Li et al., U.S. Patent No. 7,025,066 to Lawson et al., U.S. Patent Application Publication No. 2004 / 0255965 to Perfetti et al., PCT Publication No. 02 / 37990 to Bereman, and Fund. Appl. Toxicol., 39, p. 11-17 (1997), the entire disclosures of which are incorporated herein by reference.

[0054] In still other embodiments of the present disclosure, the base material may include, or consist essentially of, an extruded structure comprising tobacco, tobacco-related materials, glycerin, water, and / or binder materials, although certain formulations may not include a binder material. In various embodiments, suitable binder materials may include alginates such as ammonium alginate, propylene glycol alginate, potassium alginate, and sodium alginate. Alginates, particularly high-viscosity alginates, may be used in combination with a controlled level of free calcium ions. Other suitable binder materials include hydroxypropylcellulose such as Klucel H from Aqualon Co.; hydroxypropylmethylcellulose such as Methocel K4MS from The Dow Chemical Co.; hydroxyethylcellulose such as Natrosol 250 MRCS from Aqualon Co.; microcrystalline cellulose such as Avicel from FMC; methylcellulose such as Methocel A4M from The Dow Chemical Co.; and sodium carboxymethylcellulose such as CMC 7HF and CMC 7H4F from Hercules Inc. Still other possible binder materials include starch (e.g., corn starch), guar gum, carrageenan, locust bean gum, pectin, and xanthan gum. In some embodiments, a combination or blend of two or more binder materials may be used. Other examples of binder materials are described, for example, in U.S. Patent No. 5,101,839 to Jakob et al. and U.S. Patent No. 4,924,887 to Raker et al., each of which is incorporated herein by reference in its entirety. In some embodiments, the aerosol-forming material may be provided as part of a binder material (e.g., propylene glycol alginate). Further, in some embodiments, the binder material may contain nanocellulose derived from tobacco or other biomass.

[0055] In some embodiments, the base material may contain extruded material, as described in Stone et al., U.S. Patent Application Publication No. 2012 / 0042885, which is incorporated herein by reference in its entirety. In yet another embodiment, the base material may contain an extruded structure and / or a substrate formed from milled and / or non-milled tobacco. Milled tobacco is known, for example, by Banerjee et al., U.S. Patent No. 5,105,831, which is incorporated herein by reference in its entirety. The milled tobacco, in combination with the binders and / or flavorants described herein, contains about 20 to about 50 percent (by weight) of a tobacco blend in powder form, along with glycerol (about 20 to about 30 weight percent), calcium carbonate (generally about 10 to about 60 weight percent, often about 40 to about 60 weight percent). In various embodiments, the extruded material may have one or more longitudinal openings.

[0056] In various embodiments, the base material can take on various structures based on the various amounts of materials utilized therein. For example, a sample base material may contain up to about 98 weight percent, up to about 95 weight percent or up to about 90 weight percent of tobacco and / or tobacco-related materials. The sample base material may also contain up to about 25 weight percent, about 20 weight percent or about 15 weight percent of water, particularly about 2 weight percent to about 25 weight percent, about 5 weight percent to about 20 weight percent or about 7 weight percent to about 15 weight percent of water. Flavors and the like (e.g., including agents such as nicotine) may constitute up to about 10 weight percent, up to about 8 weight percent or up to about 5 weight percent of the aerosol delivery component.

[0057] Additionally or alternatively, the base material may comprise or consist essentially of an extruded structure and / or a base comprising tobacco, glycerin, water, and / or a binder material, and may be further configured to substantially maintain its structure throughout the aerosol generation process. That is, the base material may be configured to substantially maintain its shape throughout the aerosol generation process (e.g., the base material does not continuously deform under an applied shear stress). Such exemplary base materials may contain liquids and / or some water content, but the base may remain substantially solid throughout the aerosol generation process and may substantially maintain its structural integrity throughout the aerosol generation process. Exemplary tobaccos and / or tobacco-related materials suitable for substantially solid base materials 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., which are hereby incorporated by reference in their entirety.

[0058] In some embodiments, the amount of base material used within the smoking article may be an amount such that the article exhibits acceptable sensory and sensory irritation characteristics, as well as desirable performance characteristics. For example, in some embodiments, an aerosol precursor composition, such as glycerin and / or propylene glycol, may be used within the base material to produce a visible mainstream aerosol that resembles the appearance of tobacco smoke in many respects. For example, the amount of aerosol precursor composition incorporated into the base material of the smoking article may range from about 3.5 grams or less, about 3 grams or less, about 2.5 grams or less, about 2 grams or less, about 1.5 grams or less, about 1 gram or less, or about 0.5 grams or less.

[0059] According to another embodiment, the smoking article according to the present disclosure may include a substrate material comprising a porous inert material such as, for example, a ceramic material. For example, in some embodiments, ceramics of various shapes and outer forms (e.g., beads, rods, tubes, etc.) having various pore morphologies may be used. Further, in some embodiments, a non-tobacco material such as an aerosol precursor composition may be supported on the ceramic. In another embodiment, the substrate material may include a porous inert material that does not substantially react chemically and / or physically with a tobacco-related material such as, for example, a tobacco-derived extract. Further, extruded tobacco such as the above may be porous. For example, in some embodiments, the extruded tobacco material may have an inert gas, such as nitrogen, that functions as a foaming agent during the extrusion process.

[0060] As described above, in various embodiments, one or more of the substrate materials may include an aerosol precursor composition (e.g., a humectant such as propylene glycol, glycerin, etc.) and / or at least one flavorant, and a flame retardant / combustion retardant (e.g., diammonium phosphate and / or another salt) configured to assist in preventing ignition, pyrolysis, combustion, and / or charring of the substrate material by a heat source. Tobacco, tobacco components, and / or tobacco-derived materials that have been treated, manufactured, produced, and / or processed to incorporate such may be included. Various modes and methods for incorporating tobacco into a smoking article, particularly smoking articles designed so as not to intentionally combust substantially any of the tobacco within the smoking article, are described in U.S. Patent No. 4,947,874 to Brooks et al., U.S. Patent No. 7,647,932 to Cantrell et al., U.S. Patent No. 8,079,371 to Robinson et al., U.S. Patent 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.

[0061] As described above, in some embodiments, it may be included in one or more of the base materials, and may include flame retardant / combustion retardant materials and other additives that may include organic phosphorus compounds, borax, hydrated alumina, graphite, potassium tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Other things such as nitrogen phosphonates, monoammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ammonium ethanol borate, ammonium sulfamate, halogenated organic compounds, thiourea, and antimony oxide are also suitable but not preferred agents. In each aspect of the flame retardant materials, combustion retardant materials, and / or charring retardant materials used in the base materials and / or other components (regardless of whether alone, or in combination with each other and / or with other materials), the desired properties are most preferably provided without undesirable gas evolution or melt-type behavior.

[0062] According to other embodiments of the present disclosure, the base material may also incorporate types of tobacco additives conventionally used in the manufacture of tobacco products. These additives may include materials of the types used to enhance the flavor and aroma of tobacco used in the manufacture of cigars, cigarettes, pipes, etc. For example, these additives may contain various cigarette flavoring components and / or top layer components. See, for example, U.S. Patent No. 3,419,015 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 entire disclosures of which are incorporated herein by reference. Preferred flavoring materials may include water, sugars and syrups (e.g., sucrose, glucose and high fructose corn syrup), humectants (e.g., glycerin or propylene glycol) and flavoring agents (e.g., cocoa and licorice). These additional components may also contain top layer materials (e.g., flavorant materials such as menthol). See, for example, U.S. Patent No. 4,449,541 to Mays et al., the entire disclosure of which is incorporated herein by reference. Additional materials that may be added include those disclosed in U.S. Patent No. 4,830,028 to Lawson et al. and U.S. Patent No. 8,186,360 to Marshall et al., the entire disclosures of which are incorporated herein by reference.

[0063] In some embodiments, the base material may include a liquid containing an aerosol precursor composition and / or a gel containing an aerosol precursor composition. Some examples of liquid compositions can be found in U.S. Patent Application No. 16 / 171,920, filed October 26, 2018, entitled "Aerosol Delivery Device with Visible Indicator", the entire disclosure of which is incorporated herein by reference.

[0064] As described above, in various embodiments, one or more of the base materials may have an aerosol precursor composition bound thereto. For example, in some embodiments, the aerosol precursor composition may contain one or more different components such as a polyhydric alcohol (e.g., glycerin, propylene glycol or a mixture thereof). Representative types of additional aerosol precursor compositions are described in U.S. Patent No. 4,793,365 to Sensabaugh, Jr. et al., U.S. Patent No. 5,101,839 to Jakob et al., PCT International Publication No. 98 / 57556 to Biggs et al. and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R.J. Reynolds Tobacco Company Monograph (1988), the disclosures of which are incorporated herein by reference. In some aspects, the base material can produce a visible aerosol when sufficient heat is applied (and cooled by air if necessary), and the base material can produce a "smoky" aerosol. In other aspects, the base material can produce an aerosol that is substantially invisible but is recognized as being present by other characteristics such as flavor or texture. Thus, the nature of the aerosol produced may be variable depending on the particular components of the aerosol delivery component. The aerosol can be chemically simple compared to the chemical nature of the smoke produced by burning tobacco.

[0065] In some embodiments, the aerosol precursor composition may incorporate nicotine, which may be present in various concentrations. The source of nicotine may be various, and the nicotine incorporated into the aerosol precursor composition may be derived from a single source or a combination of two or more sources. For example, in some embodiments, the aerosol precursor composition may contain tobacco-derived nicotine. In other embodiments, the aerosol precursor composition may contain nicotine derived from other organic plant sources, such as non-tobacco plant sources including, for example, plants of the Solanaceae family. In other embodiments, the aerosol precursor composition may contain synthetic nicotine. In some embodiments, the nicotine incorporated into the aerosol precursor composition may be derived from non-tobacco plant sources such as other members of the Solanaceae family. The aerosol precursor composition may additionally or alternatively contain other active ingredients including, but not limited to, plant components (e.g., lavender, peppermint, chamomile, basil, rosemary, thyme, eucalyptus, ginger, cannabis, ginseng, maca, and tisane), stimulants (e.g., caffeine and guarana), amino acids (e.g., taurine, theanine, phenylalanine, tyrosine, and tryptophan) and / or pharmaceutical components, nutraceutical components, and medicinal components (e.g., vitamins, such as B6, B12, and C, and cannabinoids, such as tetrahydrocannabinol (THC) and cannabidiol (CBD)).

[0066] A wide variety of types of flavorants or materials that change the sensory or sensory-stimulating characteristics or properties of the mainstream aerosol of a smoking article may be suitable for use. In some embodiments, such flavorants may be provided from sources other than tobacco and may be of natural or artificial nature. For example, some flavorants may be applied to or incorporated into a substrate material and / or the area of the smoking article where the aerosol is generated. In some embodiments, such agents may be supplied directly to a heating cavity or area proximate to a heat source or provided with the substrate material. Exemplary flavorants include, for example, vanilla, ethyl vanillin, cream, tea, coffee, fruits (such as the flavors of apples, cherries, strawberries, peaches, and citrus including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, patchouli, jasmine, cascarilla, cocoa, licorice, as well as flavorants and flavor packages of the types and characteristics conventionally used in the flavoring of cigarettes, cigars, and pipe tobaccos. Syrups such as high fructose corn syrup may also be suitable for use.

[0067] The flavorant may also include acidic or basic properties (e.g., organic acids such as levulinic acid, succinic acid, pyruvic acid, and benzoic acid). In some embodiments, the flavorant can be combined with elements of the base material, if desired. Exemplary plant-derived compositions that may be suitable are disclosed in both U.S. Patent No. 9,107,453 to Dube et al. and U.S. Patent Application Publication No. 2012 / 0152265, the disclosures of which are incorporated herein by reference in their entirety. Any of the materials such as flavorings, flavorings, etc. that can be useful in combination with the tobacco material to affect its sensory properties, including the sensory stimulating properties as described herein, may be combined with the base material. In particular, incorporating an organic acid into the base material can make it possible to affect the flavor, sensory, or sensory stimulating properties of agents such as nicotine that can be combined with the base material. For example, organic acids such as levulinic acid, lactic acid, pyruvic acid, and benzoic acid may be included in the base material together with nicotine in an amount up to equimolar (based on the total organic acid content) with the nicotine. Any combination of organic acids may be suitable. For example, in some embodiments, the base material contains 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 a combination thereof, up to a concentration where the total amount of the organic acid present is equimolar to the total amount of nicotine present in the base material. Various additional examples of organic acids used to produce the base material are described in U.S. Patent Application Publication No. 2015 / 0344456 to Dull et al., the disclosure of which is incorporated herein by reference in its entirety.

[0068] The selection of such additional components may be variable based on factors such as the sensory characteristics desired in the smoking article, and the present disclosure is intended to encompass any such additional components that would be readily apparent to one of ordinary skill in the art of tobacco and tobacco-related or tobacco-derived products. See Gutcho's Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972) and Leffingwell et al.'s Tobacco Flavoring for Smoking Products (1972), the entire disclosures of which are incorporated herein by reference.

[0069] In other embodiments, the substrate material may include other materials having various unique features or properties. For example, the substrate material may include a plasticized material or regenerated cellulose in the form of rayon. As another example, viscose, a regenerated cellulose product incorporating silica (commercially available as VISIL(R)), may be suitable. Some carbon fibers may contain at least 95 percent or more carbon. Similarly, natural cellulose fibers such as cotton may be suitable, and natural cellulose fibers such as cotton may be infused with silica, carbon, or metal particles, or treated with silica, carbon, or metal particles to enhance flame retardant properties and, in particular, minimize the release of any undesirable gas emission components that would otherwise have an adverse effect on the flavor (in particular, minimizing the potential for any harmful gas emission products). To provide the desired flame retardant properties by dipping, spraying, or other techniques known in the art, it may be possible, for example, to treat cotton with boric acid or various organophosphate compounds. These fibers may also be treated with organic or metal nanoparticles (e.g., by coating, injecting, or both by dipping, spraying, or vapor deposition) to impart the desired flame retardant properties without accompanying undesirable gas emissions or melt-type behavior.

[0070] In the illustrated embodiment, the base material 116 may comprise an axis extending in a longitudinal direction defined centrally between a first end and a second end on opposite sides of each other, and the cross-section of the base material 116 may be symmetric with respect to the axis in some embodiments. For example, in some embodiments, the cross-section of the base material 116 may be substantially circular such that the base material 116 defines a generally cylindrical shape extending between its first end and second end on opposite sides of each other. However, in other embodiments, the base material may define a substantially non-circular cross-section such that the base material may define a generally non-cylindrical shape between its first end and second end on opposite sides of each other. Otherwise, in other examples, the base material may comprise an asymmetric cross-section about the axis. In various embodiments, each end of the base material may be axially aligned with an adjacent element.

[0071] As shown in FIGS. 2 and 3, the cartridge 102 of the illustrated embodiment also includes an outer housing 112 configured to surround at least a portion of a base portion 110 that includes the base material 116. In the illustrated embodiment, the outer housing 112 is also configured to surround at least a portion of the heat source 109. In the illustrated embodiment, the outer housing comprises a rigid material. For example, the outer housing 112 of the illustrated embodiment is constructed from an aluminum material, but in other embodiments, the outer housing 112 may be constructed from other metallic materials (such as stainless steel, aluminum, brass, copper, silver, gold, and bronze, etc.), or a graphite material, or a ceramic material, or a plastic material, or other materials including any combination thereof. In some embodiments, at least a portion of the heat source and / or at least a portion of the base material may be surrounded by a paper foil laminate. In some embodiments, the cartridge may comprise a housing that includes a laminate comprising a heat source and a beaded base material. Some examples of laminates and / or housings that may be applicable to the present disclosure can be found in U.S. Patent Application No. 16 / 174,846, filed Oct. 30, 2018, entitled "Smoking Article Cartridge", which is hereby incorporated by reference in its entirety.

[0072] In the illustrated embodiment, the outer housing 112 is constructed as a tube structure that substantially encapsulates the base material 116. However, as described above, in other embodiments, the outer housing 112 may have other shapes. Although the shape of the outer housing 112 can vary, in the illustrated embodiment, the outer housing 112 comprises a tube structure having an open end and a closed end. The illustrated embodiment of the outer housing 112 also includes one or more end openings 118 disposed on the closed end of the outer housing 112 configured to allow an aerosolized vapor (also referred to herein as "vapor" or "aerosol") to pass therethrough. The end openings 118 of the illustrated embodiment are in the form of a pair of elongated rounded slots. However, in other embodiments, the end openings may have any form that allows the aerosol to pass therethrough. Thus, it will be understood that the end openings 118 can comprise fewer or additional openings and / or alternative shapes and sizes of openings than those illustrated.

[0073] The heat portion 108 and the base portion 110 of the embodiments of FIGS. 1 - 3 are included and enclosed together by an outer housing forming an integrated cartridge. However, in embodiments of the present disclosure, the heat portion and the base portion comprise separate components and are configured to be removably and interchangeably independent within a holder. Thus, the user may remove and / or replace only the heat portion, or only the base portion, or both the heat portion and the base portion. For example, FIG. 4 shows a top schematic view of an aerosol delivery device according to an embodiment of the present disclosure. In particular, FIG. 4 shows a top schematic view of an aerosol delivery device 200. In the illustrated embodiment, the aerosol delivery device 200 includes a holder 202 configured to receive a heat portion 204 and a separate base portion 206. In the illustrated embodiment, the heat portion 204 includes a heat source 208 and the base portion 206 includes a base material 210. The aerosol delivery device 200 of the illustrated embodiment further includes an aerosol passage 212 extending from the base material 210 through the holder 202.

[0074] In some embodiments, the thermal portion may include an outer housing configured to surround or enclose at least a portion of the heat source. Similarly, the substrate portion of some embodiments may include an outer housing configured to surround or enclose at least a portion of the substrate material. However, it should be noted that in other embodiments, one or both of the heat source and / or the substrate material may not be enclosed by the outer housing such that the heat source and / or the substrate material is exposed. In some embodiments, the holder may further include a thermal portion compartment configured to receive the thermal portion and / or a substrate portion compartment configured to receive the substrate portion. It should be noted that the possible heat sources and / or possible substrate materials of the illustrated embodiments are the same as those described above. Accordingly, reference is made to the appropriate description of these characteristics (and their variations), which will not be repeated here.

[0075] In the illustrated embodiment, the thermal portion 204 and the substrate portion 210 are substantially longitudinally aligned in an end-to-end configuration. FIG. 5 shows a perspective schematic view of the thermal portion 204 and the substrate portion 206 of the embodiment of FIG. 5. In the illustrated embodiment, the proximal end of the heat source 208 of the illustrated embodiment is disposed proximate to the distal end of the substrate material 210. In some embodiments, the thermal portion and the substrate portion may be in contact with each other. In other embodiments, a space may exist between the thermal portion and the substrate portion. In some embodiments, a barrier may be disposed between the thermal portion and the substrate portion. In some embodiments, the barrier may be substantially porous, while in other embodiments, the barrier may be substantially non-porous. For example, reference is made to the embodiment described below with respect to FIG. 10. In some embodiments, the barrier may prevent or impede the combustion gas from being drawn through the substrate material (and / or the aerosol from being drawn through the air passage through which the air is drawn).

[0076] In some embodiments, a heat transfer component, which may or may not include a barrier, may be disposed between a heat source and a substrate material. In various embodiments, the heat transfer component can be any material, or combination of materials, configured to transfer heat from the heat source to the substrate material. For example, in some embodiments, the heat transfer component can comprise one or more conductive materials including, for example, gold, silver, copper, aluminum, stainless steel, etc., as well as combinations of these materials and laminates including one or more of these materials. In some embodiments, the heat transfer component is configured to be removably and replaceably independent within a holder. In other embodiments, the heat transfer component may be integral with one or more of the heat portion or the substrate portion. In some embodiments, the heat transfer component may form part of a non-porous barrier that can prevent or block combustion gases from being drawn through the substrate (or an aerosol from being drawn through an air passage through which the aerosol is drawn). In some embodiments, the holder, or a part of the holder (such as a receiving chamber), may be thermally conductive and may be in close contact with the heat transfer component and / or the substrate material.

[0077] In the illustrated embodiment, ignition of the heat source 208 results in aerosolization of the aerosol precursor composition coupled to the substrate material 210. In the illustrated embodiment, the aerosol passage 212 of the holder 200 is configured to receive the generated aerosol therethrough in response to suction applied to the holder 202 by a user. Although not shown, in some embodiments, the holder may include one or more air inlet openings extending through the holder in proximity to the substrate portion. Additionally or alternatively, other embodiments may include one or more air inlet openings extending through the holder downstream of the substrate portion. Thus, the drawn air may be mixed with the generated aerosol and then delivered to the user.

[0078] Another exemplary embodiment showing a top view schematic of the aerosol delivery device is shown in FIG. 6. In particular, FIG. 6 shows a top view schematic of the aerosol delivery device 300. In the illustrated embodiment, the aerosol delivery device 300 includes a holder 302 configured to receive a heat portion 304 and a separate substrate portion 306. In the illustrated embodiment, the heat portion 304 includes a heat source 308, and the substrate portion 306 includes a substrate material 310. The aerosol delivery device 300 of the illustrated embodiment further includes an aerosol passage 312 extending from the substrate portion 310 through the holder 302.

[0079] In some embodiments, the heat portion may include an outer housing configured to surround or enclose at least a portion of the heat source. Similarly, the substrate portion of some embodiments may include an outer housing configured to surround or enclose at least a portion of the substrate material. However, it should be noted that in other embodiments, one or both of the heat source and / or the substrate material may not be enclosed by the outer housing such that the heat source and / or the substrate material is exposed. In some embodiments, the holder may further include a heat portion compartment configured to receive the heat portion and / or a substrate portion compartment configured to receive the substrate portion. Note that the possible heat sources and / or possible substrate materials of the illustrated embodiment are the same as those described above. Accordingly, reference is made to the appropriate description of these characteristics (and their variations), which are not repeated here.

[0080] In the illustrated embodiment, the heat portion 304 and the substrate portion 310 are horizontally aligned in a left - right configuration (with respect to the upper part of the device 300). FIG. 7 shows a perspective schematic view of the heat portion 304 and the substrate portion 306 of the embodiment of FIG. 6. In the illustrated embodiment, the distal end of the heat source 308 is disposed proximate to the distal end of the substrate material 310. It should be noted that in other embodiments, the heat source may be disposed at any position adjacent to the substrate material. For example, in some embodiments, the heat source may be horizontally aligned in a left - right configuration (with respect to the upper part of the device) such that the heat source is disposed between the distal end and the first end of the substrate material. In other embodiments, the first end of the heat source may be substantially aligned with the first end of the substrate material.

[0081] In some embodiments, the heat portion and the substrate portion may be in contact with each other. In other embodiments, a space may exist between the heat portion and the substrate portion. In some embodiments, a barrier may be disposed between the heat portion and the substrate portion. In some embodiments, the barrier may be substantially porous, while in other embodiments, the barrier may be substantially non - porous. For example, reference is made to the embodiment described below with respect to FIG. 10. In some embodiments, the barrier may prevent or impede the combustion gas from being drawn through the substrate material (and / or the aerosol from being drawn through the air passage through which the air is drawn).

[0082] In some embodiments, the heat transfer component may be disposed between the heat source and the substrate material. In various embodiments, the heat transfer component can be any material, or combination of materials, configured to transfer heat from the heat source to the substrate material. For example, in some embodiments, the heat transfer component may comprise one or more conductive materials including, for example, gold, silver, copper, aluminum, stainless steel, etc., as well as combinations of these materials and laminates including one or more of these materials. In some embodiments, the heat transfer component is configured to be removably and replaceably independent within the holder. In other embodiments, the heat transfer component may be integral with one or more of the heat portion or the substrate portion. In some embodiments, the heat transfer component may form part of a non-porous barrier that can prevent or block combustion gases from being drawn through the substrate (or an aerosol from being drawn through an air passage through which the aerosol is drawn). In some embodiments, the holder, or a portion of the holder (such as a receiving chamber), may be thermally conductive and may be in intimate contact with the heat transfer component and / or the substrate material.

[0083] In the illustrated embodiment, ignition of the heat source 308 results in aerosolization of the aerosol precursor composition coupled to the substrate material 310. In the illustrated embodiment, the aerosol passage 312 of the holder 302 is configured to receive the generated aerosol therethrough in response to suction applied to the holder 302 by the user. Although not shown, in some embodiments, the holder may include one or more air inlet openings extending through the holder proximate the substrate portion. Additionally or alternatively, other embodiments may include one or more air inlet openings extending through the holder downstream of the substrate portion. Thus, the drawn air may be mixed with the generated aerosol and then delivered to the user.

[0084] Another exemplary embodiment showing a front schematic view of an aerosol delivery device is shown in FIG. 8. In particular, FIG. 8 shows a front schematic view of an aerosol delivery device 400. In the illustrated embodiment, the aerosol delivery device 400 includes a holder 402 configured to receive a heat portion 404 and a separate substrate portion 406. In the illustrated embodiment, the heat portion 404 includes a heat source 408, and the substrate portion 406 includes a substrate material 410. The aerosol delivery device 400 of the illustrated embodiment further includes an aerosol passage 412 extending from the substrate portion 410 through the holder 402.

[0085] In some embodiments, the heat portion may include an outer housing configured to surround or enclose at least a portion of the heat source. Similarly, the substrate portion of some embodiments may include an outer housing configured to surround or enclose at least a portion of the substrate material. However, it should be noted that in other embodiments, one or both of the heat source and / or the substrate material may not be enclosed by the outer housing such that the heat source and / or the substrate material are exposed. In some embodiments, the holder may further include a heat portion compartment configured to receive the heat portion and / or a substrate portion compartment configured to receive the substrate portion. Note that the possible heat sources and / or possible substrate materials of the illustrated embodiment are the same as those described above. Accordingly, reference is made to the appropriate description of these characteristics (and their variations), which are not repeated here.

[0086] In the illustrated embodiment, the thermal portion 404 and the substrate portion 410 are aligned in a vertical configuration (with respect to the top of the device 400). FIG. 9 shows a perspective schematic view of the thermal portion 404 and the substrate portion 406 of the illustrated embodiment of FIG. 8. In the illustrated embodiment, the distal end of the heat source 408 is disposed proximate and above the distal end of the substrate material 410. It should be noted that in other embodiments, the heat source may be disposed at any position above or below the substrate material. For example, in some embodiments, the heat source may be aligned in a vertical configuration (with respect to the top of the device) such that the heat source is disposed between the distal end and the first end of the substrate material. In other embodiments, the first end of the heat source may be substantially aligned with the first end of the substrate material.

[0087] In some embodiments, the thermal portion and the substrate portion may be in contact with each other. In other embodiments, a space may exist between the thermal portion and the substrate portion. In some embodiments, a barrier may be disposed between the thermal portion and the substrate portion. In some embodiments, the barrier may be substantially porous, while in other embodiments, the barrier may be substantially non-porous. For example, reference is made to the embodiment described below with respect to FIG. 10. In some embodiments, the barrier may prevent or impede the combustion gas from being drawn through the substrate material (and / or the aerosol from being drawn through the air passage through which the air is drawn).

[0088] In some embodiments, the heat transfer component may be disposed between the heat source and the substrate material. In various embodiments, the heat transfer component can be any material, or combination of materials, configured to transfer heat from the heat source to the substrate material. For example, in some embodiments, the heat transfer component may comprise one or more conductive materials including, for example, gold, silver, copper, aluminum, stainless steel, etc., as well as combinations of these materials and laminates including one or more of these materials. In some embodiments, the heat transfer component is configured to be removably and replaceably independent within the holder. In other embodiments, the heat transfer component may be integral with one or more of the heat portion or the substrate portion. In some embodiments, the heat transfer component may form part of a non-porous barrier that can prevent or block the combustion gas from being drawn through the substrate (or an aerosol from being drawn through an air passage through which the aerosol is drawn). In some embodiments, the holder, or a portion of the holder (such as a receiving chamber), may be thermally conductive and may be in close contact with the heat transfer component and / or the substrate material.

[0089] In the illustrated embodiment, ignition of the heat source 408 results in aerosolization of the aerosol precursor composition coupled to the substrate material 410. In the illustrated embodiment, the aerosol passage 412 of the holder 402 is configured to receive the generated aerosol therethrough in response to suction applied to the holder 402 by the user. Although not shown, in some embodiments, the holder may include one or more air inlet openings extending through the holder in proximity to the substrate portion. Additionally or alternatively, other embodiments may include one or more air inlet openings extending through the holder downstream of the substrate portion. Thus, the drawn air may be mixed with the generated aerosol and then delivered to the user.

[0090] FIG. 10 shows a schematic top view of an aerosol delivery device according to an embodiment of the present disclosure. In particular, FIG. 10 shows a schematic top view of an aerosol delivery device 500. In the illustrated embodiment, the aerosol delivery device 500 includes a holder 502 configured to receive a heat portion 504 and a separate substrate portion 506. In the illustrated embodiment, the heat portion 504 includes a heat source 508, and the substrate portion 506 includes a substrate material 510. The aerosol delivery device 500 of the illustrated embodiment further includes an aerosol passage 512 that extends from the substrate portion 510 through the holder 502.

[0091] In some embodiments, the heat portion may include an outer housing configured to surround or enclose at least a portion of the heat source. Similarly, the substrate portion of some embodiments may include an outer housing configured to surround or enclose at least a portion of the substrate material. However, it should be noted that in other embodiments, one or both of the heat source and / or the substrate material may not be enclosed by the outer housing such that the heat source and / or the substrate material is exposed. In some embodiments, the holder may further include a heat portion compartment configured to receive the heat portion and / or a substrate portion compartment configured to receive the substrate portion. Note that the possible heat sources and / or possible substrate materials of the illustrated embodiment are the same as those described above. Accordingly, reference is made to the appropriate description of these characteristics (and their variations), which are not repeated here.

[0092] In the illustrated embodiment, the heat portion 504 and the substrate portion 510 are aligned in a generally longitudinal direction with their ends facing each other. In the illustrated embodiment, the barrier 505 is disposed between the heat source 508 and the substrate material 510. In the illustrated embodiment, the barrier 505 comprises a heat transfer component. In various embodiments, the heat transfer component may be made from any material, or combination of materials, configured to transfer heat from the heat source to the substrate material. For example, in some embodiments, the heat transfer component may comprise one or more conductive materials including, for example, gold, silver, copper, aluminum, stainless steel, etc., as well as combinations of these materials and laminates including one or more of these materials. In some embodiments, the heat transfer component is configured to be removably and replaceably independent within a holder. In other embodiments, the heat transfer component may be integral with one or more of the heat portion or the substrate portion. Some examples of heat transfer components are described in U.S. Patent Application No. 15 / 923,735, filed Mar. 16, 2018, entitled "Smoking Article with Heat Transfer Component", which is hereby incorporated by reference in its entirety.

[0093] In the illustrated embodiment, the heat source 508 and the substrate material 510 are in contact with opposing portions of the barrier 505, although in other embodiments, one or both of the heat source or the substrate material may be spaced from the barrier. In some embodiments, the barrier may be substantially porous, although in other embodiments, the barrier may be substantially non-porous. In some embodiments, the heat transfer component may be disposed between the heat source and the substrate material.

[0094] In the illustrated embodiment, ignition of the heat source 508 results in aerosolization of the aerosol precursor composition coupled to the substrate material 510. In the illustrated embodiment, the aerosol passage 512 of the holder 500 is configured to receive the generated aerosol therethrough in response to suction applied to the holder 502 by the user. Although not shown, in some embodiments, the holder may include one or more air inlet openings extending through the holder proximate to the substrate portion. Additionally or alternatively, other embodiments may include one or more air inlet openings extending through the holder downstream of the substrate portion. Thus, the drawn air may be mixed with the generated aerosol and then delivered to the user.

[0095] In the illustrated embodiment, the distal end of the heat portion and the end of the substrate portion are substantially aligned with each other, but it should be noted that this may not be the case in other embodiments. For example, in some embodiments, the longitudinal axis of the heat portion may be disposed substantially parallel to the longitudinal axis of the substrate portion, but the heat portion may be disposed between the proximal and distal ends of the substrate portion. The illustrated embodiment shows the longitudinal axis of the heat portion that is substantially aligned with the longitudinal axis of the substrate portion or is substantially parallel to the longitudinal axis of the substrate portion, but it should be further noted that in other embodiments, the longitudinal axis of the heat portion may not be substantially aligned with the longitudinal axis of the substrate portion or may not be substantially parallel to the longitudinal axis of the substrate portion. For example, in some embodiments, the longitudinal axis of the heat portion may have an angle other than zero degrees, such as an offset angle (e.g., an acute angle, an obtuse angle, or a substantially perpendicular angle), with respect to the longitudinal axis of the substrate portion. In various embodiments, such angles may be in the same plane or in different planes. The aerosol delivery device according to the present disclosure can take various embodiments as described in detail herein, but the use of the aerosol delivery device by consumers is similar in terms of the scope of application. The above description of the use of the aerosol delivery device is applicable to the various embodiments described through minor modifications that will be apparent to those skilled in the art in light of the further disclosure provided herein. However, the description of the use is not intended to limit the use of the device of the present invention and is provided to meet all the necessary requirements of the disclosure herein.

[0096] In some embodiments of the present disclosure, the heat portion, the substrate portion, and the holder may generally be provided together as a complete aerosol delivery device, but these components may be provided separately. For example, the present disclosure also includes disposable units for use with reusable units. In certain embodiments, such disposable units (which may be one or more of the heat portion or the substrate portion, as shown in the accompanying figures) can be configured to engage with a reusable unit (which may be a holder as shown in the accompanying figures). In still other configurations, one or more of the heat portion or the substrate portion may include a reusable unit, and the holder may include a disposable unit.

[0097] Some of the figures described herein show the heat portion, the substrate portion, and the holder in an operational relationship, but it is understood that the heat portion and / or the substrate portion and / or the holder may exist as individual components. Thus, any description provided herein with respect to the combined components should be understood to apply to the holder and the cartridge as individual and separate components.

[0098] In another aspect, the present disclosure may be directed to a kit providing the various components described herein. For example, the kit may include a holder having one or more heat portions and / or one or more substrate portions. In further embodiments, the kit may include a plurality of heat portions and / or a plurality of substrate portions. The kit of the present invention may further include a case (or other packaging, transportation, or storage component) for housing one or more of the additional kit components. The case may be a reusable hard container or a soft container. Additionally, the case may be simply a box or other packaging structure. In some embodiments, a brush or other cleaning accessory may be included in the kit. The cleaning accessory may be configured to be inserted into the receiving chamber of the holder, or in other embodiments, may be inserted into a separate opening that allows the user to remove debris from the receiving chamber.

[0099] Having the benefit of the teachings set forth in the foregoing description and the associated drawings, many modifications and other embodiments of the present disclosure will come to mind to those of ordinary skill in the art to which this disclosure pertains. Accordingly, it is to be understood 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

**Claim 1** An aerosol delivery device comprising: a holder defining an aerosol passageway; a heat portion including a heat source configured to generate heat; a substrate portion comprising a substrate material containing an aerosol precursor composition; wherein the aerosol passageway extends from the substrate portion through the holder; the holder is configured to receive the heat portion and the substrate portion, the heat portion and the substrate portion are disposed adjacent to each other, the heat portion and the substrate portion are separate components, and the aerosol delivery device is configured such that the heat portion and the substrate portion are removably and interchangeably independent within the holder. **Claim 2** The aerosol delivery device according to claim 1, wherein the heat portion and the substrate portion are arranged with their ends facing each other. **Claim 3** The aerosol delivery device according to claim 1, wherein the heat portion and the substrate portion are arranged adjacent to each other. **Claim 4** The aerosol delivery device according to claim 1, wherein the longitudinal axis of the heat portion has an offset angle with respect to the longitudinal axis of the substrate portion. **Claim 5** The aerosol delivery device according to claim 1, wherein the heat portion and the substrate portion are arranged in a vertical configuration. **Claim 6** The aerosol delivery device according to claim 1, wherein the heat portion and the substrate portion are in contact with each other. **Claim 7** The aerosol delivery device according to claim 1, wherein there is a space between the heat portion and the substrate portion. **Claim 8** The aerosol delivery device according to claim 1, further comprising a heat transfer component disposed between the heat portion and the substrate portion. **Claim 9** The aerosol delivery device according to claim 8, wherein the heat transfer component is configured to be removably and interchangeably independent within the holder. **Claim 10** The aerosol delivery device according to claim 8, wherein the heat transfer component is integral with one or more of the heat portion or the substrate portion. **Claim 11** The aerosol delivery device according to claim 1, wherein the substrate portion includes an outer housing surrounding at least a portion of the substrate material. **Claim 12** The aerosol delivery device according to claim 1, wherein the heat portion includes an outer housing surrounding at least a portion of the heat source. **Claim 13** The aerosol delivery device according to claim 1, wherein the holder includes a heat portion compartment. **Claim 14** The aerosol delivery device according to claim 1, wherein the holder includes a substrate portion compartment. **Claim 15** The aerosol delivery device according to claim 1, wherein the holder includes a heat portion compartment and a separate substrate portion compartment.

16. The aerosol delivery device according to claim 1, wherein the heat source comprises a combustible heat source.

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