Smoking article with a heat transfer component

Abstract

To provide a smoking article that reduces carbon monoxide, carbon dioxide, and other harmful products of carbon combustion, and provides improved heat transfer to aerosol forming components.SOLUTION: The present disclosure is directed to a smoking article 100 that comprises: a heat source 104 configured to generate heat upon ignition thereof; a substrate material 106 having opposed first and second ends such that the heat source is disposed proximately to the first end of the substrate material, where the substrate material has an aerosol precursor composition associated therewith; a mouthpiece 114 disposed proximately to the second end of the substrate material; and a heat transfer component 105. The heat transfer component comprises a hollow structure and opposing first and second flanges located on respective ends thereof, where the hollow structure is such that the heat source is located between the first and second opposing flanges. The heat transfer component located within the heat source penetrates at least a portion of the substrate material, and includes a cap located between the heat source and the substrate material.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure relates to aerosol delivery devices and systems, such as smoking articles, and more particularly to aerosol delivery devices and systems that utilize a combustible carbon-based ignition source for the production of an aerosol (e.g., inhalable forms of tobacco and other substances commonly referred to as heated systems or e-cigarettes). Components of such articles are made from or derived from tobacco, or the articles can be characterized as incorporating tobacco for human consumption in other ways, and components of the tobacco and / or other tobacco-related materials can be vaporized to form an inhalable aerosol for human consumption.

Background Art

[0002] As an improvement or alternative to smoking products based on burning tobacco, many smoking articles have been proposed over the years. Exemplary alternatives include devices that burn a solid or liquid fuel to transfer heat to the tobacco, or devices in which a chemical reaction is utilized to provide such a heat source. An example is the smoking article described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference.

[0003] The points of improvement or alternatives for smoking articles have 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, numerous smoking products, flavor generators, and pharmaceutical inhalers have been proposed that utilize electrical energy to vaporize or heat volatile substances or attempt to provide the sensation of smoking a cigarette, cigar, or pipe with less combustion of the tobacco. See, for example, U.S. Patent No. 7,726,320 to Robinson et al., which is incorporated herein by reference; and U.S. Patent Application Publication No. 2013 / 0255702 to Griffith, Jr. et al., which is incorporated herein by reference; and U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., which is incorporated herein by reference, for various alternative smoking articles, aerosol delivery devices, and heat sources described in the background art. Also see, for example, U.S. Patent Application Publication No. 2015 / 0220232 to Bless et al., which is incorporated herein by reference, for various types of smoking articles, aerosol delivery devices, and electric heat sources referenced by trademark and commercial source. See also U.S. Patent Application Publication No. 2015 / 0245659 to DePiano et al., which is incorporated herein by reference in its entirety, for further types of smoking articles, aerosol delivery devices, and electric heat sources referenced by trademark and commercial source.Other representative cigarette or smoking articles described and in some cases commercially available include U.S. Patent No. 4,735,217 to Gerth; U.S. Patents Nos. 4,922,901, 4,947,874 and 4,947,875 to Brooks; 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 Publications Nos. 2006 / 0196518, 2009 / 0126745 and 2009 / 0188490 to Hon; U.S. Patent Application Publication No. 2009 / 0272379 to Thorens; U.S. Patent Application Publications Nos. 2009 / 0260641 and 2009 / 0260642 to Monsees; U.S. Patent Application Publications Nos. 2008 / 0149118 and 2010 / 0024834 to Oglesby; U.S. Patent Application Publication No. 2010 / 0307518 to Wang; and those described in WO2010 / 091593 to Hon, and these documents are incorporated herein by reference.

[0004] A variety of ways and methods have been proposed for assembling smoking articles having a plurality of sequentially arranged segmented components. For example, U.S. Patent No. 5,469,871 to Barnes et al. and U.S. Patent No. 7,647,932 to Crooks et al.; and U.S. Patent Application Publication No. 2010 / 0186757 to Crooks et al.; Publication No. 2012 / 0042885 to Stone et al.; and Publication No. 2012 / 00673620 to Conner et al. have described various types of assembly techniques and methodologies. Each of these is hereby incorporated by reference in its entirety.

[0005] Typical products that resemble many of the attributes of traditional paper-wrapped cigarettes, cigars, or pipes include ACCORD(R) by Philip Morris Incorporated; ALPHA(trademark), JOYE 510(trademark), and M4(trademark) by InnoVapor LLC; CIRRUS(trademark) and FLING(trademark) by White Cloud Cigarettes; BLU(trademark) by Fontem Ventures B.V.; COHITA(trademark), COLIBRI(trademark), ELITE CLASSIC(trademark), MAGNUM(trademark), PHANTOM(trademark), and SENSE(trademark) by EPUFFER(R) International Inc.; DUOPRO(trademark), STORM(trademark), and VAPORKING(R) by Electronic Cigarettes, Inc.; EGAR(trademark) by Egar Australia; eGo-C(trademark) and eGo-T(trademark) by Joyetech; ELUSION(trademark) by Elusion UK Ltd; EONSMOKE(R) by Eonsmoke LLC; FIN(trademark) by FIN Branding Group, LLC; SMOKE(R) by Green Smoke Inc. USA; GREENARETTE(trademark) by Greenarette LLC; HALLIGAN(trademark), HENDU(trademark), JET(trademark), MAXXQ(trademark), PINK(trademark), and PITBULL(trademark) by SMOKE STIK(R); HEATBAR(trademark) by Philip Morris International, Inc.; HYDRO IMPERIAL(trademark) and LXE(trademark) obtained from Crown7; LOGIC(trademark) and THE CUBAN(trademark) by Logic Technology; LUCI(R) by Luciano Smokes Inc.; METRO(R) by Nicotek, LLC; NJOY(R) and ONEJOY(trademark) by Sottera, Inc.; NO.7(trademark) by SS Choice LLC; PREMIUM ELECTRONIC CIGARETTE(trademark) by PremiumEstore LLC; Ruyan America, Inc.Sold under the trademarks RAPP E-MYSTICK by [trademark owner 1]; RED DRAGON by Red Dragon Products, LLC; RUYAN (R) by Ruyan Group (Holdings) Ltd.; SF (R) by Smoker Friendly International, LLC; GREEN SMART SMOKER (R) by The Smart Smoking Electronic Cigarette Company Ltd; SMOKE ASSIST (R) by Coastline Products LLC; SMOKING EVERYWHERE (R) by Smoking Everywhere, Inc.; V2CIGS (trademark) by VMR Products LLC; VAPOR NINE (trademark) by VaporNine LLC; VAPOR4LIFE (R) by Vapor 4 Life, Inc.; VEPPO (trademark) by E-CigaretteDirect, LLC; VUSE (R) by R.J. Reynolds Vapor Company; Mistic Menthol products by Mistic Ecigs; and Vype products by CN Creative Ltd.; IQOS (trademark) by Philip Morris International; and GLO (trademark) by British American Tobacco. Additionally, other electric aerosol delivery devices, particularly those characterized as so-called electronic cigarettes, have been sold under the trade names COOLER VISIONS (trademark); DIRECT E-CIG (trademark); DRAGONFLY (trademark); EMIST (trademark); EVERSMOKE (trademark); GAMUCCI (R); HYBRID FLAME (trademark); KNIGHT STICKS (trademark); ROYAL BLUES (trademark); SMOKETIP (R); and SOUTH BEACH SMOKE (trademark).

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Patent Document 38

Patent Document 39

Patent Document 40

Summary of the Invention

Problems to be Solved by the Invention

[0007] In some examples, conventional smoking articles such as those referenced above are difficult to assemble as a result of multiple components that must be disassembled and reassembled upon consumption of the aerosol delivery components provided. Also, in some other examples, some smoking articles, particularly those using a conventional paper wrapper, are prone to charring of the paper wrapper over the ignitable fuel source because high temperatures are achieved by a fuel source proximate to the paper wrapper. This can reduce the enjoyment of the smoking experience for some consumers and may mask or otherwise alter the flavor delivered to the consumer by the aerosol delivery components of the smoking article. In further examples, conventional smoking articles may produce relatively high 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 suffer from inadequate performance with respect to aerosolizing aerosol-forming components.

[0008] Accordingly, it is desirable to provide a smoking article that addresses one or more of the technical problems sometimes associated with conventional smoking articles. In particular, it is desirable to provide a smoking article that reduces carbon monoxide, carbon dioxide, and / or other harmful products of carbon combustion and / or provides improved heat transfer to aerosol-forming components.

Means for Solving the Problems

[0009] The present disclosure provides a smoking article. The present disclosure includes, without limitation, the following embodiments.

[0010] Embodiment 1: A smoking article comprising a heat source configured to generate heat upon ignition, a base material having opposing first and second ends, wherein the heat source is disposed proximate the first end of the base material, the base material having an associated aerosol precursor composition, a mouthpiece disposed proximate the second end of the base material, and a heat transfer component including a hollow structure portion and opposing first and second flanges disposed at respective ends, wherein the hollow structure portion of the heat transfer component extends through the heat source such that the heat source is positioned between the first and second opposing flanges of the heat transfer component, and the hollow structure portion is configured to permit passage of air.

[0011] Embodiment 2: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the base material includes at least one of tobacco-containing beads, tobacco shreds, tobacco strips, fragments of reconstituted tobacco material, tobacco rods, and non-tobacco materials.

[0012] Embodiment 3: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, further comprising a liner configured to surround the base material and at least a portion of the heat source.

[0013] Embodiment 4: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, further comprising one or more perforations disposed in the base material, the perforations being configured to facilitate air flow through the smoking article.

[0014] Embodiment 5: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, further comprising a second base material having opposing first and second ends, the second base material being disposed between the first base material and the mouthpiece.

[0015] Embodiment 6: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the second base material comprises at least one of tobacco-containing beads, tobacco flakes, tobacco strips, fragments of reconstituted tobacco material, or a tobacco rod.

[0016] Embodiment 7: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the mouthpiece comprises an intermediate component.

[0017] Embodiment 8: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the mouthpiece comprises a filter.

[0018] Embodiment 9: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the heat source comprises an extruded monolithic carbonaceous material.

[0019] Embodiment 10: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the extruded monolithic carbonaceous material defines one or more grooves extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material.

[0020] Embodiment 11: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the base material comprises a series of overlapping layers of an initial base sheet.

[0021] Embodiment 12: A smoking article comprising a heat source configured to generate heat upon ignition, a substrate material having opposing first and second ends, the heat source being disposed proximate the first end of the substrate material, the substrate material having an aerosol precursor composition associated therewith, a mouthpiece disposed proximate the second end of the substrate material, and a heat transfer component disposed within the heat source, the heat transfer component extending from the heat source and penetrating at least a portion of the substrate material, the heat transfer component including a cap disposed between the heat source and the substrate material.

[0022] Embodiment 13: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the heat transfer component includes one or more substantially closed-end structures.

[0023] Embodiment 14: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein one or more closed-end structures are composed of at least one of aluminum and copper having an aluminum coating.

[0024] Embodiment 15: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the heat transfer component includes one or more substantially solid rods.

[0025] Embodiment 16: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein one or more substantially solid rods are composed of at least one of aluminum and copper having an aluminum coating.

[0026] Embodiment 17: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the heat transfer component includes an aluminum mesh.

[0027] Embodiment 18: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the heat transfer component further comprises an aluminum disk disposed at a position along the length of the aluminum mesh.

[0028] Embodiment 19: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the heat transfer component comprises one or more substantially solid sheets.

[0029] Embodiment 20: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the one or more substantially solid sheets are composed of at least one of aluminum and copper having an aluminum coating.

[0030] Embodiment 21: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the base material comprises at least one of tobacco-containing beads, tobacco shreds, tobacco strips, fragments of reconstituted tobacco material, or a tobacco rod.

[0031] Embodiment 22: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, further comprising a liner configured to surround the base material and at least a portion of the heat source.

[0032] Embodiment 23: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, further comprising a second base material having opposing first and second ends, the second base material being disposed between the first base material and the mouthpiece.

[0033] Embodiment 24: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the second base material comprises at least one of tobacco-containing beads, tobacco shreds, tobacco strips, fragments of reconstituted tobacco material, or a tobacco rod.

[0034] Embodiment 25: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the mouthpiece comprises an intermediate component.

[0035] Embodiment 26: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the mouthpiece comprises a filter.

[0036] Embodiment 27: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the heat source comprises an extruded monolithic carbonaceous material.

[0037] Embodiment 28: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the extruded monolithic carbonaceous material defines one or more grooves extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material.

[0038] Embodiment 29: A smoking article according to any preceding embodiment, or any combination of any preceding embodiments, wherein the substrate material comprises a series of overlapping layers of an initial substrate sheet.

[0039] 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.

[0040] Although the present disclosure has been described in this manner under prior general conditions, reference is now made to the accompanying drawings, which are not necessarily drawn to scale. BRIEF DESCRIPTION OF THE DRAWINGS

[0041]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

DETAILED DESCRIPTION OF THE INVENTION

[0042] The present disclosure will now be described more fully hereinafter with reference to its embodiments. These embodiments are described so that the present disclosure will be thorough and complete and will fully convey the scope of the 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 set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise.

[0043] The present disclosure presents an account of articles (and assemblies and / or their manufacture) in which materials are heated (preferably without burning the materials to any significant extent) to form aerosols and / or inhalable substances. Such articles are most preferably sufficiently simple to be considered “handheld” devices. In preferred embodiments, the article is characterized as a smoking article. As used herein, the term “smoking article” means an article and / or device that provides many of the sensations of smoking a cigarette, cigar, or pipe (e.g., the habitual acts of inhalation and exhalation, multiple types of taste or flavor, sensory effects, physical sensations, habitual acts of use, visual cues, such as those obtained by visible aerosols, etc.) without any substantial degree of combustion of 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 device or article produces a vapor (including vapors within an aerosol that may be considered a visible aerosol to be described as a smoke analogue) resulting from the volatilization or vaporization of specific components, elements, etc. of the article and / or device. In preferred embodiments, the article or device characterized as a smoking article incorporates tobacco and / or tobacco-derived components.

[0044] The articles or devices of the present disclosure are also characterized as vapor-generating articles, aerosol delivery articles, or drug delivery articles. Thus, such articles or devices are adaptable to supply one or more substances in an inhalable form or state. For example, the inhalable substance is substantially in the form of vapor (e.g., a substance in the gas phase at a temperature below the critical point). Alternatively, the inhalable substance is in the form of an aerosol (e.g., a suspension of fine solid particles or droplets of a gas). For the purpose of brevity, the term "aerosol" as used herein means to include vapor, gas, and aerosol, whether visible or not, and whether or not in a form that might be considered to be a likely form, and whether or not in a form that might be considered to be similar to smoke, in a form or type suitable for human inhalation.

[0045] In use, the smoking articles of the present disclosure expose an individual to many physical acts when using conventional smoking articles (e.g., cigarettes, cigars, or pipes that are used by lighting a fire and then inhaling the burning and / or combusted tobacco). For example, a user of a smoking article of the present disclosure holds the article in a manner quite similar to a conventional smoking article and draws one end of the article into the mouth to inhale the aerosol generated by the article and inhales at selected time intervals.

[0046] In this specification, the systems are generally described with respect to embodiments related to smoking articles such as so-called "electronic cigarettes" or "tobacco heating products", but it should be understood that the mechanisms, components, features, and methods can be embodied in many different forms and can be associated with a variety of articles. For example, the descriptions provided herein can be employed in combination with embodiments of conventional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heated cigarettes, and related packages for any of the products disclosed herein. Thus, it should be understood that the descriptions of the mechanisms, components, features, and methods disclosed herein are described only with respect to embodiments related to aerosol delivery devices by way of example and can be embodied and used in many other various products and methods.

[0047] The smoking articles of the present disclosure generally include a plurality of elements provided in or included in a certain kind of enclosure, such as a housing, an outer wrapper, or a wrapper, a casing, components, modules, members, etc. The overall design of the enclosure is variable, and the form or configuration of the enclosure that defines the overall size and shape of the smoking article is also variable. In some embodiments, it is desirable that the overall design, size and / or shape of the enclosure be similar to that of a conventional cigarette or cigar. Typically, an enclosure having a shape similar to that of a cigarette or cigar includes three or more separable components, members, etc. that engage to form the enclosure. For example, such a smoking article may, in some embodiments, include three separable components including a mouthpiece component, an aerosol delivery component (e.g., a base material, etc.) and a heat source component. In various embodiments, the heat source can generate heat to aerosolize a base material including materials naturally found in tobacco, such as, for example, an extrusion structure and / or a base material related to the base, an aerosol precursor composition, tobacco and / or tobacco-related materials, such as solids or liquids (e.g., beads, sheets, flakes, wraps) isolated directly from tobacco or prepared synthetically. In some embodiments, the extrusion structure can include a tobacco product or a composite of tobacco and other materials, such as ceramic powder. In other embodiments, a porous ceramic bead can be filled with a tobacco extract / slurry. In other embodiments, non-tobacco products may be used. For example, in some embodiments, porous beads / powders (ceramics) filled with e-liquid may be used. In other embodiments, rods / cylinders made of an extrusion slurry of ceramic powder and e-liquid can be used.

[0048] According to certain aspects of the present disclosure, it may be advantageous to provide a smoking article that reduces carbon monoxide and / or carbon dioxide and / or other harmful products of carbon combustion and / or improves heat transfer to aerosol-forming components. FIGS. 1 and 2 show perspective views of such a smoking article. In particular, FIG. 1 shows a perspective view of a smoking article 100 including an outer wrapper 102, and FIG. 2 shows a smoking article 100 in which the outer wrapper 102 and a liner 118 (described below) have been removed to expose other components of the smoking article 100. Referring to FIG. 2, in addition to the outer wrapper 102 and the liner 118, the smoking article of the illustrated embodiment includes a heat source 104, a heat transfer component 105, a first inhalable material medium 106, a second inhalable material medium 108, an intermediate component 110, and a filter 112. In the illustrated embodiment, the intermediate component 110 and the filter 112 together form a mouthpiece 114.

[0049] The smoking articles according to the present disclosure can take various embodiments, as discussed in detail below, but the scope of use of the smoking articles by consumers is the same. The foregoing description of the use of the smoking article can be applied to the various embodiments described through minor modifications. The embodiments 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 articles of the invention, but is presented to meet all the necessary requirements disclosed herein.

[0050] In various embodiments, the heat source 104 may be configured to generate heat upon ignition thereof. In the illustrated embodiment, the heat source 104 has a generally cylindrical shape and includes a combustible fuel element incorporating a combustible carbonaceous material. In other embodiments, the heat source 104 can have a different shape, for example, a prism shape having a cubic or hexagonal cross-section. The carbonaceous material generally has a high carbon content. Preferred carbonaceous materials are mainly composed of carbon and / or typically have a carbon content of more than about 60 percent, generally more than about 70 percent, frequently more than about 80 percent, and often more than about 90 percent on a dry weight basis.

[0051] In some cases, the heat source 104 may incorporate elements other than the combustible carbonaceous material (e.g., components of tobacco such as powdered tobacco or tobacco extracts; flavorants; salts such as sodium chloride, potassium chloride, and sodium carbonate; thermally stable graphite 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). The specific dimensions of the applicable heat source may vary, but in the illustrated embodiment, the heat source 104 has a length in the inclusive range of about 7 mm to about 20 mm, and in some embodiments, may be about 17 mm, and in an inclusive range of an overall diameter of about 3 mm to about 8 mm, and in some embodiments may be about 4.8 mm (about 7 mm in some embodiments). In other embodiments, the heat source can be constructed in various ways, but in the illustrated embodiment, the heat source 104 is extruded or compounded using a pulverized or powdered carbonaceous material and, on a weight basis when dry, exceeds about 0.5 g / cm 3 and frequently exceeds about 0.7 g / cm 3 and often exceeds about 1 g / cm 3 and has a density exceeding this. See, for example, the types of fuel source components, formulations, and designs described in U.S. Patent No. 5,551,451 to Riggs et al. and U.S. Patent No. 7,836,897 to Borschke et al. Those documents are hereby incorporated by reference in their entirety. In various embodiments, the heat source can have various forms, including, for example, a substantially solid cylindrical shape or a hollow cylindrical (e.g., tube) shape, but the heat source 104 of the illustrated embodiment includes an extruded monolithic carbonaceous material. This is substantially cylindrical but has a plurality of grooves 116 extending longitudinally from a first end of the extruded monolithic carbonaceous material to a second end opposite the first end of the extruded monolithic carbonaceous material. In the illustrated embodiment, the heat source 104 has a passage 117 defined therethrough (see FIG. 3). As will be discussed in more detail below, in various embodiments, the passage 117 is configured to receive a portion of the heat transfer component 105.

[0052] In the illustrated embodiment, the grooves 116 of the heat source 104 are substantially equal in width and depth and are substantially equally distributed around the circumference of the heat source 104, although other embodiments may include only two grooves, and still other embodiments may include a single groove. Still other embodiments may not include any grooves at all. Additional embodiments may include a plurality of grooves, which may not be equal in width and / or depth and may be arranged at unequal intervals around 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 an opposite second end. In some embodiments, the heat source may include a foamed carbon monolith formed in a foaming process of the type disclosed in U.S. Patent No. 7,615,184 to Lobovsky, which is 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 U.S. Patent No. 4,922,901 to Brooks et al., or other heat source embodiments such as those disclosed in U.S. Patent Application Publication No. 2009 / 0044818 to Takeuchi et al., each of which is hereby incorporated by reference in its entirety.

[0053] Generally, a heat source is disposed sufficiently close to an aerosol delivery component (e.g., a base material) that includes one or more aerosolizable components such that an aerosol formed / volatilized by application of heat from the heat source to the aerosolizable component (and any flavorants, medicaments, etc. similarly supplied for delivery to a user) is deliverable to the user via a mouthpiece. That is, when the heat source heats the base component, an aerosol is formed, released, or produced in a physical form suitable for inhalation by a consumer. It should be noted that the foregoing terms are interchangeable, and thus, references to releasing (release, releasing, releases), released include forming or generating (form or generate, forming or generating, forms or generates), formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol or a mixture thereof. Further, the selection of various smoking article elements is evaluated in view of commercially available electronic smoking articles such as representative products described in the background art section of the present disclosure.

[0054] Figure 3 shows a schematic longitudinal cross - section of the smoking article 100 of FIG. 1 according to one embodiment of the present disclosure. In various embodiments, the outer wrapper 102 (most clearly shown in FIG. 1) is provided to engage at least a portion of the heat source 104 with at least a portion of the first substrate material 106, the second substrate material 108, and the mouthpiece 114, or otherwise to apply them together. Thus, the outer wrapper material 102 is configured in some aspects to surround, for example coaxially surround, at least a portion of the heat source 104. The first substrate material 106 engages the heat source 104 around its first end, and the second substrate material 108 engages the second end of the first substrate material 106 and at least a portion of the mouthpiece 114. The outer wrapper 102 is configured to be held in the wound position by any means, including adhesives or fasteners, to allow the outer wrapper 102 to remain in the wound position. Otherwise, in some other aspects, the outer wrapper 102 may be configured to be removable if desired. For example, when the outer wrapper 102 is held in the wound position, the outer wrapper 102 can be removed from the heat source 104, the first substrate material 106 engages the heat source 104 around its first end, and the second substrate material 108 can engage the second end of the first substrate material 106 and / or the mouthpiece 114.

[0055] As shown in the figures, in addition to the outer wrapper 102, the illustrated embodiments also include a liner 118 configured to surround at least a portion of the first base material 106 and at least a portion of the heat source 104. In other embodiments, the liner 118 can surround only a portion of the length of the first base material 106, but in some embodiments, the liner 118 can also surround the second base material 108. In some embodiments, the outer wrapper material 102 can include the liner 118. Thus, in some embodiments, the outer wrapper material 102 and the liner 118 can be separate materials that are made together (e.g., joined together as a laminate by bonding, fusing, or other means). In other embodiments, the outer wrapper 102 and the liner 118 can be the same material. In any case, the liner 118 can be configured to thermally condition the conduction of heat generated by the ignited heat source 104 radially outward of the liner 118. Thus, in some embodiments, the liner 118 can be composed of a metal foil material, a graphene material, a graphite material, or other thermally conductive carbon-based material and / or an aluminum material, and in some embodiments, can include a laminate. In the illustrated embodiment, the liner 118 is composed of an aluminum laminate. In some embodiments, depending on the material of the outer wrapper 102 and / or the liner 118, a layer of thin insulation can be provided radially outward of the liner 118. Thus, in some respects, the liner 118 can advantageously provide a way to engage two or more separate components of the smoking article 100 (e.g., the heat source 104 and the first base material 106, etc.), while also providing a way to limit heat conduction radially outward while promoting heat transfer axially along it.

[0056] Also, as shown in FIG. 3, the outer wrap 102 (and optionally the liner 118 and the first substrate material 106) can also include one or more openings 120 formed such that air can enter when the mouthpiece 114 is drawn in. In various embodiments, the size and number of these openings are such that a larger portion of the drawn air flow occurs through these openings (in some embodiments, a greater air flow rate), and a smaller portion of the air flow occurs through the hollow structure described below (in some embodiments, a lesser air flow rate). In such a manner, the air flow through the hollow structure can be, or is generally, for the sole purpose of facilitating heat transfer. In some embodiments, the openings 120 can be disposed between the distal end of the heat transfer component 105 and the first substrate material 106. In some embodiments, the openings 120 can be formed in the outer wrap 102 (and in some embodiments, the liner 118) in a region proximate to the first substrate material 106, and one or more separate cooling openings 121 can be formed in the outer wrap 102 (and in some embodiments, the liner 118) in a region proximate to the filter 112. In the illustrated embodiment, a plurality of substantially equally spaced openings 120 are formed in the outer wrap 102 and the liner 118 in a region proximate to the first substrate material 106, and a plurality of substantially equally spaced separate cooling openings 121 are formed in the outer wrap 102 in a region proximate to the mouthpiece 114 (e.g., proximate to the filter 112). In various embodiments, the plurality of openings can be formed through the outer wrap 102 (and the liner 118) in various ways, but in the illustrated embodiment, the plurality of openings 120 and the plurality of separate cooling openings 121 are formed by laser drilling.

[0057] FIG. 4 shows a perspective view of the heat source 104 and the heat transfer component 105 of the smoking article 100 of FIG. 1 according to an embodiment of the present disclosure. FIG. 5 shows a perspective view of the heat transfer component 105 of the smoking article 100 of FIG. 1 according to an embodiment of the present disclosure. In particular, FIG. 4 shows that the heat transfer component 105 includes a hollow structure 122 having a first flange 124 disposed proximate one end thereof and a second flange 126 disposed proximate the second end thereof. As shown in FIGS. 3 and 4, the heat source 105 is disposed between the first flange 124 and the second flange 126 such that the hollow structure 122 (see FIG. 5) of the heat transfer component 105 extends through the heat source 104, particularly through the passage 117 of the heat source 104. In the illustrated embodiment, the hollow structure is shown in the form of a hollow tube, but in other embodiments, the hollow structure can have any other non-cylindrical hollow shape. In the illustrated embodiment, the hollow structure 122, the first flange 124, and the second flange 126 of the heat transfer component 105 are made of aluminum. However, in other embodiments, any one or any combination of these parts may be constructed of another heat conductive material including, for example, stainless steel, brass, copper, silver, gold, bronze, graphite, ceramics (such as alumina, beryllia, boron nitride, aluminum nitride, silicon carbide, etc.) and / or combinations thereof. Further, any one or any combination of these parts may be composed of one or more materials (e.g., one conductive material) and coated with another material (e.g., another conductive material).

[0058] In the illustrated embodiment, the first flange 124 and the second flange 126 are attached to the hollow structure 122 proximate to their respective ends using laser welding and / or brazing / soldering. However, in other embodiments, other attachment and / or construction methods may be used. For example, in some embodiments, the heat transfer component 105 can be constructed from a single piece. In other embodiments, one or more adhesives and / or other mechanical attachment means (e.g., press-fitting or screw engagement) can be used. In some embodiments, the thickness of the flanges 124, 126 can be in an inclusive range of about 0.05 mm to about 1 mm, and in some embodiments, can be about 0.1 mm to 0.2 mm. The inner diameter of the hollow structure 122 can be in an inclusive range of about 0.1 mm to about 3 mm, and in some embodiments, can be about 0.3 mm to 0.7 mm. The wall thickness of the hollow structure 122 can be in an inclusive range of about 0.05 mm to about 1 mm, and in some embodiments, can be about 0.1 to 0.2 mm. The flanges of the illustrated embodiment have a substantially circular profile, but in other embodiments, one or both of the flanges can have other shapes, including, for example, a substantially elliptical profile and / or a substantially polygonal profile, such as profiles of triangles, rectangles, squares, pentagons, hexagons, heptagons, octagons, etc.

[0059] In one embodiment, the diameter of the first flange 124 (in other embodiments, the overall size) may be approximately equal to the outer diameter of the heat source. However, in other embodiments (such as the embodiment shown in FIG. 3), the diameter of the first flange 122 may be smaller than the outer diameter of the heat source 104. As will be described below, such a configuration can promote air circulation in the grooves of the heat source 104. In still other embodiments, the diameter of the first flange 122 may be larger than the outer diameter of the heat source 104. In various embodiments, the diameter of the first flange 124 can be between 1 / 3 and 4 / 3 times the diameter of the heat source 104. In the illustrated embodiment, the diameter of the first flange 124 can be approximately 3 / 4 times the size of the diameter of the heat source 104. In some embodiments, the diameter of the second flange 126 can vary, but in the illustrated embodiment, the diameter of the second flange 126 is approximately the same as the outer diameter of the heat source 104. Further, in various embodiments, the length of the hollow structure portion 122 can be at least as long as the length of the heat source 104, and in some embodiments, it can extend into the first base material 106 (see, for example, FIG. 11), and in still other embodiments, it can further extend into the second base material 108.

[0060] In various embodiments, the hollow structure portion 122 of the heat transfer component may be open at its ends so that air can flow through the hollow structure portion 122. In this way, when the user draws on the mouthpiece 114 of the smoking article 100, air can move through the heat transfer component 105. In this way, the air moving through the hollow structure portion 122 may be in addition to the air entering the smoking article 100 through the opening 120 formed through the first base material 106 and the outer wrap 102 (and optionally the liner 118) proximate to the mouthpiece 114. Thus, in addition to the heat transfer function provided by the structure of the heat transfer component 105, the heat transfer component 105 facilitates the transfer of heat from the heat source 104 to the first base material 106 through conduction (and / or subsequent heat conduction, e.g., the second base material 108, etc.), and the passage of air through the hollow structure portion 122 of the heat transfer component 105 during drawing on the smoking article 100 further facilitates the transfer of heat from the heat source 104 to the first base material 106 (and / or subsequent base materials) by convection. Note that in still other embodiments, the hollow structure portion 122 connecting the first flange 124 and the second flange 126 need not be hollow, and thus, a solid connecting component (e.g., a solid cylinder) may be used to connect the first flange 124 and the second flange 126. In such embodiments, air does not pass through the heat transfer component.

[0061] In the illustrated embodiment, the smoking article 100 also includes a first substrate material 106 having opposing first and second ends, the first end being disposed proximate to the heat transfer component 105. While various embodiments may include only one substrate material, in the illustrated embodiment, a second substrate material 108 is disposed proximate to the second end of the first substrate material 106. In other embodiments, additional substrate materials can be included. In various embodiments, one or more of the substrate materials can include tobacco or tobacco-related materials, along with the associated aerosol precursor composition. Other possible compositions, components, and / or additives for use with the substrate material(s) are described in more detail below. It should be noted that the following discussion is applicable to any substrate material (e.g., the first substrate material 106 and / or the second substrate material 108, individually or together) that can be used in the smoking articles described herein.

[0062] In some embodiments, the base material can include a blend of flavorful aromatic tobaccos in cut filler form. In another embodiment, the base material can include reconstituted tobacco materials 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. These disclosures are hereby incorporated by reference in their entirety. Further, the reconstituted tobacco materials can include reconstituted tobacco paper 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 contents thereof are hereby incorporated by reference in their entirety. For example, the reconstituted tobacco material can include a sheet-like material that includes tobacco and / or tobacco-related materials. Thus, in some embodiments, the base material can be formed from a rolled roll of reconstituted tobacco material. In another embodiment, the base material can be formed from shreds, strips, etc. of reconstituted tobacco material. In another embodiment, the tobacco sheet may or may not include a heat conductive component and may include overlapping layers (e.g., a gathered web). An example of a base portion including a series of overlapping layers (e.g., a gathered 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 Publication No. 15 / 905,320, filed February 26, 2018, entitled Heat Conducting Substrate For Electrically Heated Aerosol Delivery Device, which is hereby incorporated by reference in its entirety.

[0063] In some embodiments, the base material can include a plurality of microcapsules, beads, granules, etc. that contain tobacco-related materials. For example, a typical microcapsule can have a substantially spherical shape and can have an outer cover or shell that contains a liquid core region such as an extract derived from tobacco. In some embodiments, one or more of the base materials can include a plurality of microcapsules each formed in a hollow cylindrical shape. In some embodiments, one or more of the base materials can include a binder material configured to maintain the structural shape and / or integrity of a plurality of microcapsules formed in a hollow cylindrical shape.

[0064] The tobacco used in one or more of the base materials can include or be derived from tobacco such as flue-cured Virginia tobacco, Burley tobacco, Oriental tobacco, Maryland tobacco, Dark tobacco, dark air-cured tobacco, and Rustica tobacco, other rare or special tobacco, or blends thereof. The types of one or more various representative tobaccos, processed types of tobacco, 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 et al.; 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.; International Publication No. 02 / 37990 to Bereman; and Bombick et al. Fund. Appl. Toxicol., 39, pp. 11-17 (1997); the disclosures of which are hereby incorporated by reference in their entirety.

[0065] In still other embodiments of the present disclosure, the base material can be configured as an extruded structure that includes, or consists essentially of, tobacco, tobacco-related materials, glycerin, water, and / or binder materials, although specific formulations can exclude binder materials. In various embodiments, suitable binder materials can include alginates such as ammonium alginate, propylene glycol alginate, potassium alginate, and sodium alginate. Alginates, particularly high-viscosity alginates, can be used in combination with controlled levels 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 250MRCS from Aqualon Co.; microcrystalline cellulose such as Avicel from FMC; methylcellulose such as Methocel A4M from The Dow Chemical Co.; sodium carboxymethylcellulose such as CMC 7HF and CMC 7H4F from Hercules Inc. Still other possible binder materials include starches (e.g., corn starch), guar gum, carrageenan, locust bean gum, pectin, and xanthan gum. In some embodiments, combinations or blends of two or more binder materials can 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 these documents being incorporated herein by reference in its entirety. In some embodiments, the aerosol-forming material can be provided as part of a binder material (e.g., propylene glycol alginate). Further, in some embodiments, the binder material can include nanocellulose derived from tobacco or other biomass.

[0066] In some embodiments, the base material may be configured as an extruded material as described in U.S. Patent Application Publication No. 2012 / 0042885 to Stone, which is hereby incorporated by reference in its entirety. In yet another embodiment, the base material may include an extruded structure and / or a substrate formed from marlized and / or non-marlized tobacco. Marlized tobacco is known, for example, from U.S. Patent No. 5,105,831 to Banerjee, which is hereby incorporated by reference in its entirety. Marlized tobacco includes from about 20 to about 50 percent (by weight) of a tobacco blend in powder form, glycerol (from about 20 to about 30 percent by weight), calcium carbonate (generally from about 10 to about 60 weight percent, frequently from about 40 to about 60 weight percent), with a binder agent and / or flavorant as described herein. In various embodiments, the extruded material can have one or more longitudinal openings.

[0067] In various embodiments, the base material can take on various structures based on the various amounts of materials utilized therein. For example, a sample of the base material can include 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. A sample of the base material may include up to about 25 weight percent, about 20 weight percent, or about 15 weight percent, particularly from about 2% to about 25%, from about 5% to about 20%, or from about 7% to about 15 weight percent of water. Flavors and the like (e.g., including agents such as nicotine) can 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.

[0068] Additionally or alternatively, the base material may be configured as, or include or consist essentially of, an extruded structure and / or a base material that includes tobacco, glycerin, water, and / or a binder material, and is 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 applied shear stress). Such exemplary base materials may include a liquid and / or some water content, but the base material 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.

[0069] In some embodiments, the amount of base material used within the smoking article can be an amount such that the article exhibits acceptable sensory and organoleptic properties, as well as desirable performance characteristics. For example, in some embodiments, an aerosol precursor composition, such as glycerin and / or propylene glycol, can be used within the base material to provide 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 can 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.

[0070] According to another embodiment, the smoking article according to the present disclosure can include a base material including a porous inert material such as, for example, a ceramic material. For example, in some embodiments, ceramics of various shapes and geometries (e.g., beads, rods, tubes, etc.) having various pore morphologies may be used. Further, in some embodiments, a non-tobacco material such as an e-liquid can be loaded into the ceramic. In another embodiment, the base material can include a porous inert material that does not substantially react chemically and / or physically with a tobacco-related material such as, for example, an extract derived from tobacco. Further, extruded tobacco such as the above can be porous. For example, in some embodiments, the extruded tobacco material can have an inert gas such as nitrogen that functions as a foaming agent during the extrusion process.

[0071] As described above, in various embodiments, one or more of the base materials 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 (such as diammonium phosphate and / or another salt) configured to help prevent ignition, pyrolysis, combustion, and / or charring of the base material by a heat source. It may include tobacco, tobacco components, and / or tobacco-derived materials that have been treated, manufactured, produced, and / or processed to incorporate them. Various ways and methods for incorporating tobacco into a smoking article, particularly smoking articles designed such that substantially all of the tobacco within those smoking articles is not intentionally burned, 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 disclosures of which are hereby incorporated by reference in their entirety.

[0072] As described above, in some embodiments, flame retardant substances and other additives that can be included in one or more of the base materials and that can include organic phosphorus compounds, borax, hydrated alumina, graphite, potassium tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Other substances such as nitrogen-containing phosphonic acids, ammonium monophosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ammonium ethanol borate, ammonium sulfamate, halogenated organic compounds, thiourea, and antimony oxide are also suitable but are not preferred agents. In each aspect of the flame retardant and / or char suppression material used in the base material and / or other components (alone or together with each other and / or in combination with other materials), the desired properties are most preferably provided without undesirable off-gas or melting type operation.

[0073] According to other embodiments of the present disclosure, the base material may also incorporate tobacco additives of the types conventionally used in the manufacture of tobacco products. These additives can 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 can include various cigarette casings and / or top dressing components. See, for example, U.S. Patent No. 3,419,015 to Wochnowski; U.S. Patent No. 4,054,145 to Berndt et al.; U.S. Patent No. 4,887,619 to Burcham, Jr. et al.; U.S. Patent No. 5,022,416 to Watson; U.S. Patent No. 5,103,842 to Strang et al.; and U.S. Patent No. 5,711,320 to Martin; the disclosures of which are hereby incorporated by reference in their entirety. Preferred casing materials can include water, sugars and syrups (e.g., sucrose, glucose and high fructose corn syrup), humectants (e.g., glycerin or propylene glycol) and flavorants (e.g., cocoa and licorice). These additional components can also include top dressing materials (e.g., flavor materials such as menthol). See, for example, U.S. Patent No. 4,449,541 to Mays et al. The disclosure of which is hereby incorporated by reference in its entirety. Further materials that can 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 disclosures of which are hereby incorporated by reference in their entirety.

[0074] As described above, in various embodiments, one or more of the base materials may have an aerosol precursor composition associated therewith. For example, in some embodiments, the aerosol precursor composition may include 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 WO98 / 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 with air if desired), and the base material can produce a "smokelike" 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 can vary depending on the particular components of the aerosol delivery component. The base material can be chemically simpler compared to the chemical nature of the smoke produced by burning tobacco.

[0075] A wide variety of types of flavorants or materials that change the sensory or organoleptic characteristics or properties of the mainstream aerosol of a smoking article may be suitable for use. In some embodiments, such flavorants may be supplied from sources other than tobacco and may be of natural or artificial nature. For example, some flavorants may be applied to or incorporated into the 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 the heating cavity or area closest to the heat source or may be provided with the substrate material. Examples of flavorants include, for example, vanilla, ethyl vanillin, cream, tea, coffee, fruits (e.g., apple, cherry, strawberry, peach, citrus flavors, including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, patchouli, jasmine, cassia, cocoa, licorice and flavors and flavor packages of the types and characteristics conventionally used in the flavors of cigarettes, cigars and pipe tobacco. Syrups such as high fructose corn syrup may also be suitable for use.

[0076] The flavorant can also include acidic or basic characteristics (e.g., organic acids such as levulinic acid, succinic acid, and pyruvic acid). In some embodiments, the flavorant may be combinable, if desired, with elements of the substrate material. Exemplary plant-derived compositions that may be suitable are disclosed in U.S. Patent No. 9,107,453 to Dube et al. and U.S. Patent Application Publication No. 2012 / 0152265, the disclosures of which are incorporated herein by reference in their entirety. Any material such as a flavor, casing, etc. that is useful in combination with the tobacco material to affect sensory properties, including the functional properties as described herein, can be combined with the substrate material. Organic acids can in particular be incorporated into the substrate material to affect the flavor, sensory, or sensory-stimulating properties of agents such as nicotine that can be combined with the substrate material. For example, organic acids such as levulinic acid, lactic acid, and pyruvic acid may be included in a substrate material containing 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 substrate 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 combinations thereof, up to a concentration such that the total amount of organic acid present is equimolar with the total amount of nicotine present in the substrate material. Various additional examples of organic acids used to produce the substrate material are described in U.S. Patent Application Publication No. 2015 / 0344456 to Dull et al. This document is incorporated herein by reference in its entirety.

[0077] The selection of such additional components can 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, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972). The disclosures of which are hereby incorporated by reference in their entirety.

[0078] In other embodiments, the first substrate material may include other materials having various unique properties or characteristics. For example, the substrate material may include a plasticized material or regenerated cellulose in the form of rayon. As another example, viscose (commercially available as VISIL(R)), a regenerated cellulose product incorporating silica, may be suitable. Some carbon fibers may contain at least 95% or more carbon. Similarly, natural cellulose fibers such as cotton may be suitable and can be treated by injecting or otherwise processing with silica, carbon, or metal particles to enhance flame retardancy and minimize the generation of off-gases, particularly any undesirable off-gas components, with minimal adverse effects on flavor (especially minimizing the potential for any toxic off-gas products). Cotton can be treated, for example, with boric acid or various organic phosphate compounds, and desirable flame retardancy can be provided by dipping, spraying, or other techniques known in the art. These fibers can also be treated with organic or metal nanoparticles (coating, injecting, or both, e.g., by dipping, spraying, or vapor deposition) to impart desirable flame retardant properties without undesirable off-gases or melting-type behavior.

[0079] Referring again to FIGS. 1 and 2, in the smoking article 100 of the illustrated embodiment, the first base material 106 includes a plurality of tobacco beads formed in a substantially cylindrical portion. As described above, in various embodiments, the size and shape of the first base material can vary. For example, in some embodiments, the first base material 106 can have a length in the inclusive range of about 5 mm to about 15 mm and an overall diameter in the inclusive range of about 3 mm to about 8 mm. In the illustrated embodiment, the first base material 106 has a length of about 10 mm and a diameter of about 4.8 mm (and in some embodiments, about 7 mm). In the illustrated embodiment, the second base material 108 includes a plurality of tobacco rods formed in a substantially cylindrical portion. Similarly, in various embodiments, the size and shape of the second base material 108 can vary. For example, in some embodiments, the second base material 108 can have a length in the inclusive range of about 5 mm to about 25 mm and an overall diameter in the inclusive range of about 3 mm to about 8 mm. In the illustrated embodiment, the second base material 108 has a length of about 10 mm and a diameter of about 4.8 mm (and in some embodiments, about 7 mm).

[0080] In the illustrated embodiment, the first substrate material 106 and the second substrate material 108 may each include a longitudinally extending axis defined centrally between respective opposing first and second ends, and the cross-sections of the first substrate material 106 and the second substrate material 108 may, in some embodiments, be symmetric with respect to the axis. For example, in some embodiments, the cross-sections of the first substrate material 106 and the second substrate material 108 may be substantially circular such that the first substrate material 106 and the second substrate material 108 define a substantially cylindrical shape extending between their opposing first and second ends. However, in other embodiments, the first substrate material 106 and the second substrate material 108 may define a substantially non-circular cross-section such that one or both of the first substrate material 106 or the second substrate material 108 can define a substantially non-cylindrical shape between the opposing first and second ends on the opposite side. Otherwise, in other examples, one or both of the first substrate material 106 or the second substrate material 108 can include an asymmetric cross-section about the axis. In various embodiments, each end of the first substrate material 106 and the second substrate material 108 may be axially aligned with an adjacent element. For example, the first end of the second substrate material 108 may be configured to be coaxially aligned with the second end of the first substrate material 106 upon engagement.

[0081] The smoking article of the illustrated embodiment also includes an intermediate component 110 and at least one filter 112. It should be noted that in various embodiments, the intermediate component 110 or the filter 112 may be regarded as the mouthpiece 114 of the smoking article 100, either individually or together. In various embodiments, neither the intermediate component nor the filter need be included, but in the illustrated embodiment, the intermediate component 110 includes a substantially rigid member that is substantially non-flexible along the longitudinal axis. In the illustrated embodiment, the intermediate component 110 has a hollow tube structure and is included to add structural integrity to the smoking article 100 and to cool the generated aerosol. In some embodiments, the intermediate component 110 may be used as a container for collecting the aerosol. In the illustrated embodiment, the filter 112 is included to filter the aerosol generated by the base materials 106 and / or 108 before being inhaled by the user. In various embodiments, such tubes may be constructed from any of a variety of materials and may include one or more adhesives. Examples of materials include, but are not limited to, paper, layers of paper, cardboard, plastic, cardboard, and / or composite materials. In the illustrated embodiment, the intermediate component 110 includes a hollow cylindrical element composed of a paper or plastic material (e.g., ethyl vinyl acetate (EVA), or other polymer materials such as polyethylene, polyester, silicone, etc., or ceramic (e.g., silicon carbide, alumina, etc.), or other acetate fibers), and the filter includes a filled rod or cylindrical disk composed of a gas-permeable material (e.g., cellulose acetate or fibers such as paper or rayon, or polyester fibers). The filter 112 may additionally or alternatively contain strands of tobacco-containing material as described in U.S. Patent No. 5,025,814 to Raker et al., which is hereby incorporated by reference in its entirety.In various embodiments, the size and shape of the intermediate component 110 and / or the filter 112 may vary. For example, the length of the intermediate component 110 may be in an inclusive range of about 10 mm to about 30 mm, the diameter of the intermediate component 110 may be in an inclusive range of about 3 mm to about 8 mm, the length of the filter 112 may be in an inclusive range of about 10 mm to about 20 mm, and the diameter of the filter 112 may be in an inclusive range of about 3 mm to about 8 mm. In the illustrated embodiment, the intermediate component 110 has a length of about 20 mm and a diameter of about 4.8 mm (and about 7 mm in some embodiments), and the filter 112 has a length of about 15 mm and a diameter of about 4.8 mm (or about 7 mm in some embodiments).

[0082] In various embodiments, the mouthpiece 114 (e.g., the intermediate component 110 and / or the filter 112) is configured to receive the generated aerosol in response to a draw applied to the mouthpiece 114 by a user. In some embodiments, the mouthpiece 114 may be engaged to fix to a base material (such as the base material 108). For example, adhesives, bonds, welding, etc. may be suitable for engaging the mouthpiece 114 to fix it to the base material 108. In one example, the mouthpiece 114 is ultrasonically welded and sealed to the second end of the base material 108.

[0083] As described, in some embodiments, the mouthpiece 114 may include a filter 112 configured to receive the aerosol in response to a draw applied to the mouthpiece 114. In various embodiments, the filter 112 is provided as a circular disk arranged radially and / or longitudinally proximate to the second end of the intermediate component 108 in some manner. In this way, when the mouthpiece 114 is drawn, the filter 112 receives the aerosol flowing through the intermediate component 110 of the smoking article 100.

[0084] In various embodiments, ignition of the heat source 104 results in aerosolization of the aerosol precursor composition associated with the first substrate material 106 and the second substrate material 108. Preferably, the elements of the first substrate material 106 and the second substrate material 108 do not undergo any significant degree of thermal decomposition (e.g., carbonization, charring, or combustion), and the aerosolized components enter the user's mouth along with the air drawn through the smoking article 100 that includes the filter 112.

[0085] FIG. 6 shows a schematic longitudinal cross - sectional view of a smoking article 200 according to another embodiment of the present disclosure. In particular, FIG. 6 shows a smoking article 200 that includes an outer wrapper 202, a heat source 204, a heat transfer component 205, a first inhalable material medium 206, a second inhalable material medium 208, and a filter 212. The filter 212 may constitute a mouthpiece 214.

[0086] In various embodiments, the heat source 204 may be configured to generate heat upon its ignition. In the illustrated embodiment, the heat source 204 has a generally cylindrical shape and includes a combustible fuel element incorporating a combustible carbonaceous material. The carbonaceous material generally has a high carbon content. Preferred carbonaceous materials are mainly composed of carbon and / or typically have a carbon content of more than about 60 percent, generally more than about 70 percent, frequently more than about 80 percent, and often more than about 90 percent on a dry weight basis.

[0087] In some cases, the heat source 204 may incorporate elements other than combustible carbonaceous materials (e.g., components of tobacco such as powdered tobacco or tobacco extracts; flavorants; salts such as sodium chloride, potassium chloride, and sodium carbonate; thermally stable graphite 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). The specific dimensions of the applicable heat source may vary, but in the illustrated embodiment, the heat source 204 has a length in an inclusive range of about 7 mm to about 20 mm, and in some embodiments, it may be about 17 mm, and in an inclusive range of an overall diameter of about 3 mm to about 8 mm, and in some embodiments it may be about 4.8 mm (about 7 mm in some embodiments). In other embodiments, the heat source can be constructed in various ways, but in the illustrated embodiment, the heat source 204 is extruded or compounded using a pulverized or powdered carbonaceous material and has a density, on a weight basis when dry, of greater than about 0.5 g / cm 3 and frequently greater than about 0.7 g / cm 3 and often greater than about 1 g / cm 3 For example, see U.S. Patent No. 5,551,451 to Riggs et al. and U.S. Patent No. 7,836,897 to Borschke et al. for types of fuel source components, formulations, and designs. Those documents are hereby incorporated by reference in their entirety.

[0088] In various embodiments, the heat source can have various forms, including, for example, a substantially solid cylindrical shape or a hollow cylinder (e.g., a tube) shape. However, the heat source 204 of the illustrated embodiment includes an extruded monolithic carbonaceous material. This defines a plurality of grooves (not visible in FIG. 6) that extend longitudinally from a first end of the extruded monolithic carbonaceous material to a second end opposite the first end of the extruded monolithic carbonaceous material. In the illustrated embodiment, the grooves are substantially equal in width and depth and are substantially equally distributed around the heat source 204. However, other embodiments can include a single groove. Other embodiments may include a plurality of grooves that may not be equal in width and / or depth and may be arranged at unequal intervals around the heat source. In yet other embodiments, the heat source can include flutes and / or slits that extend longitudinally from a first end to an opposite second end of the extruded monolithic carbonaceous material. In some embodiments, the heat source can include a foamed carbon monolith formed by a foaming process of the type disclosed in U.S. Patent No. 7,615,184 to Lobovsky, which is hereby incorporated by reference in its entirety. Thus, some embodiments may offer advantages with respect to reducing the time taken to ignite the heat source. In another embodiment, the heat source can 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 U.S. Patent No. 4,922,901 to Brooks et al. or other heat source embodiments such as those disclosed in U.S. Patent Application Publication No. 2009 / 0044818 to Takeuchi et al., each of which is hereby incorporated by reference in its entirety.

[0089] Generally, a heat source is disposed sufficiently close to a base material that includes one or more aerosolizable components such that an aerosol formed / volatilized by the application of heat from the heat source to the base material (and one or more flavorants, medicaments, etc. similarly supplied for delivery to a user) is deliverable to the user via a mouthpiece. That is, when the heat source heats the base material, an aerosol is formed, emitted, or generated in a physical form suitable for inhalation by a consumer. It is noted that the foregoing terms are interchangeable such that references to releasing (release, releasing, releases), released include forming or generating (form or generate, forming or generating, forms or generates), formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol or a mixture thereof. Further, the selection of the various smoking article elements is evaluated in view of commercially available electronic smoking articles such as the exemplary products described in the background art section of the present disclosure.

[0090] In the illustrated embodiment, the heat transfer component 205 includes a hollow cylindrical tube that is closed at one or both ends, extends through a portion of the heat source 204, and penetrates a portion of the first base material 206. It should be noted that in other embodiments, the heat transfer component can include a solid rod (such as the heat transfer component 275 shown in FIG. 7). In various embodiments, the heat transfer component can extend through any portion of the heat source 204 and can penetrate any portion of the base material. In some embodiments, the heat transfer component 205 can further extend into a portion of the second base material 208. In the illustrated embodiment, the heat transfer component 205 extends substantially the entire length of the heat source 204 and penetrates substantially the entire length of the first base material 206.

[0091] In the illustrated embodiment, the heat transfer component 205 is composed of a material that is copper coated with an aluminum material. However, in other embodiments, the heat transfer component may be composed of other heat conductive materials including, for example, stainless steel, brass, copper, aluminum, silver, gold, bronze, graphite, with or without coating, and combinations thereof. Further, any one or any combination of these parts may be composed of one material (e.g., one conductive material) and coated with another material (e.g., another conductive material). In the illustrated embodiment, the heat transfer component has a diameter in an inclusive range of about 1 mm to about 3 mm, an inner diameter in an inclusive range of about 0.5 mm to about 2.5 mm, and a length in an inclusive range of about 10 mm to about 35 mm. In this way, the heat transfer component 205 facilitates the transfer of heat from the heat source 204 to the first substrate material 206 (and, in some embodiments, additional substrate materials).

[0092] In the illustrated embodiment, the smoking article 200 also includes a first substrate material 206 having opposing first and second ends, with the first end being disposed proximate to the heat transfer component 205. While various embodiments may include only one substrate material, in the illustrated embodiment, a second substrate material 208 is disposed proximate to the second end of the first substrate material 206. In other embodiments, additional substrate materials can be included. In various embodiments, one or more of the substrate materials can include tobacco or tobacco-related materials along with the associated aerosol precursor composition. Other possible compositions, components, and / or additives for use with the first substrate material and / or the second substrate material and / or any other substrate material are described in more detail below.

[0093] In some embodiments, the base material can include a blend of flavorful aromatic tobaccos in cut filler form. In another embodiment, the base material can include reconstituted tobacco materials 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. Further, the reconstituted tobacco materials can include reconstituted tobacco papers 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 content of which is incorporated herein by reference in its entirety. For example, the reconstituted tobacco material can include a sheet-like material including tobacco and / or tobacco-related materials. Thus, in some embodiments, the base material can be formed from a rolled roll of reconstituted tobacco material. In another embodiment, the base material may be formed from pieces, strips, etc. of reconstituted tobacco material.

[0094] In some embodiments, the base material can include a plurality of microcapsules, beads, granules, etc. including tobacco-related materials. For example, representative microcapsules can be substantially spherical in shape and can have an outer cover or shell including a liquid core region such as an extract derived from tobacco. In some embodiments, one or more of the base materials can include a plurality of microcapsules each formed in a hollow cylindrical shape. In some embodiments, one or more of the base materials can include a binder material configured to maintain the structural shape and / or integrity of a plurality of microcapsules formed in a hollow cylindrical shape.

[0095] The tobacco used in one or more of the base materials can include, or be derived from, tobaccos such as flue-cured Virginia tobacco, Burley tobacco, Oriental tobacco, Maryland tobacco, dark tobacco, dark air-cured tobacco, and rusticated tobacco, other rare or special tobaccos, or blends thereof. Various representative types of tobacco, processed types of tobacco, 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 et al.; 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.; International Publication No. 02 / 37990 to Bereman; and Bombick et al., Fund. Appl. Toxicol., 39, p. 11-17 (1997); the disclosures of which are hereby incorporated by reference in their entirety.

[0096] In still other embodiments of the present disclosure, the substrate material can be configured as an extruded structure that includes, or consists essentially of, tobacco, tobacco-related materials, glycerin, water, and / or binder materials, although certain formulations exclude binder materials. The binder material can be any binder material commonly used in tobacco formulations, including, for example, carboxymethyl cellulose (CMC), gums (such as guar gum), xanthan, pullulan, and / or alginate. In some aspects, the binder material included in the substrate material can be configured to substantially maintain the structural shape and / or integrity of the substrate material. Various representative binders, binder properties, binder usage, and binder amounts are described in U.S. Patent No. 4,924,887 to Raker et al., which is hereby incorporated by reference in its entirety.

[0097] In some embodiments, the substrate material may be configured as an extruded material as described in U.S. Patent Application Publication No. 2012 / 0042885 to Stone et al., which is hereby incorporated by reference in its entirety. In yet another embodiment, the substrate material can include an extruded structure and / or substrate formed from marlized and / or non-marlized tobacco. Marlized tobacco is known, for example, from U.S. Patent No. 5,105,831 to Banerjee et al., which is hereby incorporated by reference in its entirety. Marlized tobacco includes from about 20 to about 50 percent (by weight) of a tobacco blend in powder form, glycerol (from about 20 to about 30 percent by weight), calcium carbonate (generally from about 10 to about 60 weight percent, frequently from about 40 to about 60 weight percent), and a binder agent and / or flavorant as described herein.

[0098] In various embodiments, the base material can take on various structures based on the various amounts of materials utilized therein. For example, the base material of a sample can include up to about 98 wt%, up to about 95 wt%, or up to about 90 wt% of tobacco and / or tobacco-related materials. The base material of a sample can also include up to about 25 wt%, about 20 wt%, or about 15 wt%, particularly about 2% to about 25%, about 5% to about 20%, or about 7% to about 15 wt% of water. Flavors, etc. (e.g., including agents such as nicotine) can constitute up to about 10 wt%, up to about 8 wt%, or up to about 5 wt% of the aerosol delivery component.

[0099] Additionally or alternatively, the base material can be configured as or to include a base that includes an extruded structure and / or tobacco, glycerin, water, and / or binder material and that is further configured to substantially maintain its structure throughout the aerosol generation process. That is, the base material can be configured to substantially maintain its shape throughout the aerosol generation process (e.g., the base material does not continuously deform under applied shear stress). Such exemplary base materials can include liquids and / or some water content, but the base can remain substantially solid throughout the aerosol generation process and can substantially maintain its structural integrity throughout the aerosol generation process. Exemplary tobacco 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.

[0100] In some embodiments, the amount of the base material used within the smoking article can be an amount such that the article exhibits acceptable sensory and organoleptic properties, as well as desirable performance characteristics. For example, in some embodiments, a sufficient aerosol precursor composition, such as glycerin and / or propylene glycol, can be used within the base material to result in the generation of a visible mainstream aerosol that in many respects resembles the appearance of tobacco smoke. For example, the amount of the aerosol precursor composition incorporated into the base material of the smoking article can 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.

[0101] According to another embodiment, a smoking article according to the present disclosure includes a base material including a porous inert material, such as a ceramic material. In another aspect, the aerosol delivery component includes a porous inert material that does not chemically and / or physically substantially react with a tobacco-related material, such as an extract derived from tobacco.

[0102] As described above, in various embodiments, one or more of the base 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 (e.g., diammonium phosphate and / or another salt) configured to facilitate preventing ignition, pyrolysis, combustion, and / or charring of the aerosol delivery components by a heat source. Thus, the tobacco, tobacco components, and / or tobacco-derived materials may be processed, manufactured, produced, and / or processed to incorporate the flame retardant. Various methods and ways of incorporating tobacco into smoking articles, particularly smoking articles designed so as not to intentionally burn substantially all of the tobacco within them, 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 disclosures of which are hereby incorporated by reference in their entirety.

[0103] In some embodiments, flame retardants and other additives that can be included in one or more of the base materials may include organic phosphorus compounds, borax, hydrated alumina, graphite, potassium tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Other materials such as nitrogen-containing phosphonic acids, ammonium monophosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ammonium ethanol borate, ammonium sulfamate, halogenated organic compounds, thiourea, and antimony oxide are suitable but not preferred agents. In each aspect of the flame retardant and / or char suppression material used in the aerosol delivery component and / or other components (alone or in combination with each other and / or with other materials), the desirable properties are most preferably provided without undesirable off-gassing or melting-type behavior.

[0104] According to other embodiments of the present disclosure, the base material may also incorporate tobacco additives of the types conventionally used in the manufacture of tobacco products. These additives can 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 can include various cigarette casings and / or top dressing components. See, for example, U.S. Patent No. 3,419,015 to Wochnowski; U.S. Patent No. 4,054,145 to Berndt et al.; U.S. Patent No. 4,887,619 to Burcham, Jr. et al.; U.S. Patent No. 5,022,416 to Watson; U.S. Patent No. 5,103,842 to Strang et al.; and U.S. Patent No. 5,711,320 to Martin; the disclosures of which are hereby incorporated by reference in their entirety. Preferred casing materials can include water, sugars and syrups (e.g., sucrose, glucose and high fructose corn syrup), humectants (e.g., glycerin or propylene glycol) and flavorants (e.g., cocoa and licorice). These additional ingredients can also include top dressing materials (e.g., flavor materials such as menthol). See, for example, U.S. Patent No. 4,449,541 to Mays et al. The disclosure of which is hereby incorporated by reference in its entirety. Further materials that can 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 disclosures of which are hereby incorporated by reference in their entirety.

[0105] As described above, in various embodiments, one or more of the base materials may have an aerosol precursor composition associated therewith. For example, in some embodiments, the aerosol precursor composition may include 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 WO98 / 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 aerosol delivery component can produce a visible aerosol when sufficient heat is applied (and cooled with air if necessary), and the aerosol delivery component can produce a "smokelike" aerosol. In other aspects, the aerosol delivery component 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 can vary depending on the particular components of the aerosol delivery component. The aerosol delivery component can be chemically simpler compared to the chemical nature of the smoke produced by burning tobacco.

[0106] A wide variety of types of flavorants or materials that change the sensory or organoleptic characteristics or properties of the mainstream aerosol of a smoking article may be suitable for use. In some embodiments, such flavorants may be supplied from sources other than tobacco and may be of natural or artificial nature. For example, some flavorants may be applied to or incorporated into the 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 the heating cavity or area closest to the heat source or may be provided with the substrate material. Examples of flavorants include, for example, vanilla, ethyl vanillin, cream, tea, coffee, fruits (e.g., apple, cherry, strawberry, peach, citrus flavors, including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, patchouli, jasmine, cassia, cocoa, licorice and flavors and flavor packages of the types and characteristics conventionally used in the flavors of cigarettes, cigars and pipe tobacco. Syrups such as high fructose corn syrup may also be suitable for use.

[0107] The flavorant can also include acidic or basic characteristics (e.g., organic acids such as levulinic acid, succinic acid, and pyruvic acid). In some embodiments, the flavorant may be combinable with elements of the substrate material, if appropriate. Examples of exemplary plant-derived compositions that may be suitable are disclosed in U.S. Patent No. 9,107,453 to Dube et al. and U.S. Patent Application Publication No. 2012 / 0152265, the disclosures of which are hereby incorporated by reference in their entirety. Any material such as a flavor, casing, etc. that is useful in combination with the tobacco material to affect the sensory properties, including the functional properties as described herein, can be combined with the substrate material. Organic acids in particular may be incorporated into the substrate material to affect the flavor, sensory, or sensory stimulating properties of agents such as nicotine that can be combined with the substrate material. For example, organic acids such as levulinic acid, lactic acid, and pyruvic acid may be included in a substrate material containing 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 substrate 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 combinations thereof, up to a concentration where the total amount of organic acids present is equimolar with the total amount of nicotine present in the substrate material. Various additional examples of organic acids used in manufacturing aerosol delivery components are described in U.S. Patent Application Publication No. 2015 / 0344456 to Dull et al.

[0108] Such further component selections may be variable based on factors such as the sensory characteristics desired in the smoking article and are intended to encompass any such further 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, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972). The disclosures of which are hereby incorporated by reference in their entirety.

[0109] In other embodiments, the first substrate material 206 can include other materials having various unique properties or characteristics. For example, the first substrate material 206 can include a plasticized material or regenerated cellulose in the form of rayon. As another example, viscose (commercially available as VISIL(R)), a regenerated cellulose product incorporating silica, may be suitable. Some carbon fibers may contain at least 95% or more carbon. Similarly, natural cellulose fibers such as cotton may be suitable and can be injected or otherwise treated with silica, carbon, or metal particles to enhance flame retardancy and minimize the generation of off-gases, particularly any undesirable off-gas components, having an adverse effect on flavor (particularly minimizing the potential for any toxic off-gas products). Cotton can be treated, for example, with boric acid or various organic phosphate compounds to provide the desired flame retardancy by dipping, spraying, or other techniques known in the art. These fibers can also be treated with organic or metal nanoparticles (coating, injection, or both, e.g., by dipping, spraying, or vapor deposition) to impart desirable flame-retardant properties without undesirable off-gases or melt-type operation.

[0110] The smoking article 200 of the illustrated embodiment also includes a heat transfer cap 207 configured to cover an end of the heat source 204 proximate to the first substrate material 106. In some embodiments, the cap 207 may be pressed against the end of the heat source 204. In the illustrated embodiment, the heat transfer cap 207 includes an end 207A that covers substantially the entire end of the heat source 204 proximate to the first substrate material 206, and a rim portion 207B that extends upwardly and peripherally around at least a portion of the length of the heat source 204. In the illustrated embodiment, the rim portion 207B of the heat transfer cap 207 extends for about 1 / 3 to 1 / 2 of the length of the heat source 204. In the illustrated embodiment, the heat transfer cap 207 is composed of the same material as the heat transfer component 205. However, in other embodiments, one or both of the heat transfer component 505 or the heat transfer cap 507 may be constructed of a different material, as described herein. Additionally, in various embodiments, one or both of the heat transfer component 205 or the heat transfer cap 207 may be composed of one material (e.g., one conductive material) and coated with another material (e.g., another conductive material).

[0111] In the illustrated embodiment, the heat transfer component 205 extends through a portion of the heat source 204 and extends through a portion of the first substrate material 206, particularly substantially the entire length of the first substrate material 206. However, in other embodiments, the heat transfer component 205 may extend through any portion of the heat source 204, may penetrate any portion of the first substrate material, and in some embodiments, may further extend into a portion of the second substrate material.

[0112] As described above, in some embodiments, the smoking article 200 can further include a second substrate material 208 having opposing first and second ends. In various embodiments, the second substrate material 208 can include an axis extending longitudinally and defined centrally between each of the opposing first and second ends. Similar to the first substrate material 206 in some embodiments, the cross-section of the second substrate material 208 can be symmetric with respect to the axis in some embodiments. For example, in some embodiments, the cross-sections of the first substrate material 206 and the second substrate material 208 can be substantially circular such that the first and second substrate materials 206, 208 define a substantially cylindrical shape extending between their opposing first and second ends. However, in other embodiments, the first and second substrate materials 206, 208 can define a substantially non-circular cross-section such that one or both of the first substrate material 206 or the second substrate material 208 can define a substantially non-cylindrical shape between the opposing first and second ends on the opposite side. Otherwise, in other examples, one or both of the first substrate material 206 or the second substrate material 208 can include an asymmetric cross-section about the axis. In various embodiments, each end of the first and second substrate materials 206, 208 can be axially aligned with an adjacent element. For example, the first end of the second substrate material 208 can be configured to be coaxially aligned with the second end of the first substrate material 206 upon engagement.

[0113] In various embodiments, ignition of the heat source 204 results in aerosolization of the aerosol precursor compositions associated with each of the first substrate material 206 and the second substrate material 208. Preferably, the elements of the first substrate material 206 and the second substrate material 208 do not undergo thermal decomposition (e.g., carbonization, charring, or combustion) to any significant extent, and the aerosolized components enter the user's mouth along with the air drawn through the smoking article 200 including the filter 212.

[0114] Referring back to FIG. 6, the outer wrap 202 is provided to engage at least a portion of the heat source 204 with at least a portion of the first substrate material 206, the second substrate material 208, and the mouthpiece 214, or otherwise to be applied together. Thus, in some embodiments, the outer wrap 202 is configured to surround, for example coaxially surround, at least a portion of the heat source 204, the first substrate material 206 engages the heat source 204 around its first end, and the second substrate material 208 engages the second end of the first substrate material 206 and at least a portion of the mouthpiece 214. The outer wrap 202 is configured to be held in the wound position in any manner, including by adhesives or fasteners, to enable the outer wrap 202 to remain in the wound position. Otherwise, in some other embodiments, the outer wrap 202 may be configured to be removable if desired. For example, when the outer wrap 202 is held in the wound position, the outer wrap 202 can be removed from the heat source 204, the first substrate material 206 engages the heat source 204 around its first end, and the second substrate material 208 can engage the second end of the first substrate material 206 and a portion of the mouthpiece 214. In this example, adhesives, fasteners, etc. are removed and the outer wrap 202 is not circumscribed around it.

[0115] As shown in the figures, in addition to the outer wrapper 202, the depicted embodiments also include a liner 218 configured to surround at least a portion of the first substrate material 206 and the heat source 204. In some embodiments, the liner 218 may also surround the second substrate material 208. In some embodiments, the outer wrapper material 202 may include the liner 218. Thus, in some embodiments, the outer wrapper material 202 and the liner 218 can be separate materials that are made together (e.g., joined together as a laminate by bonding, fusing, or other means). In other examples, the outer wrapper 202 and the liner 218 can be the same material. In any case, the liner 218 can be configured to thermally condition the conduction of heat generated by the ignited heat source 204 radially outward of the liner 218. Thus, in some embodiments, the liner 218 can be composed of a foil material, a graphene material, a graphite material, and / or an aluminum material, and in any case, the material can be a laminate. In the illustrated embodiment, the liner is composed of an aluminum laminate. In some embodiments, depending on the material of the outer wrapper 202 and / or the liner 218, a layer of thin insulation can be provided radially outward of the liner 218. Thus, the liner 218, in some aspects, advantageously provides a way to engage two or more separate components of the smoking article 200 (e.g., the heat source 204 and the first substrate material 206, etc.), while also providing a way to limit heat conduction radially outward while promoting heat transfer axially along it.

[0116] Also, as shown in FIG. 6, the outer wrap 202 (and optionally the liner 218 and the first substrate material 206) can also include one or more openings 220 formed such that air can enter when the mouthpiece 214 is drawn in. In some embodiments, the opening 220 can be disposed between the distal end of the heat transfer component 205 and the first substrate material 206. In some embodiments, the opening 220 can be formed in the outer wrap 202 (and in some embodiments, the liner 218) in a region proximate the first substrate material 206, and separate cooling openings 221 can be formed in the outer wrap 202 (and, in some embodiments, the liner 218) in a region proximate the filter 212. In the illustrated embodiment, a plurality of substantially equally spaced openings 220 are formed in the outer wrap 202 and the liner 218 in a region proximate the first substrate material 206, and a plurality of substantially equally spaced separate cooling openings 221 are formed in the outer wrap 202 in a region proximate the mouthpiece 214 (e.g., proximate the filter 212 in the illustrated embodiment). In various embodiments, the openings can be formed through the outer wrap 202 (and the liner 218) in various ways, but in the illustrated embodiment, the plurality of openings 220 are formed by laser drilling.

[0117] In the smoking article 200 of the illustrated embodiment, the first base material 206 includes a plurality of tobacco beads formed in a substantially cylindrical portion. As described above, in various embodiments, the size and shape of the first base material can vary. For example, the first base material 206 can have a length in the inclusive range of about 5 mm to about 15 mm and an overall diameter in the inclusive range of about 3 mm to about 8 mm. In the illustrated embodiment, the first base material 206 has a length of about 10 mm and a diameter of about 4.8 mm (and in some embodiments, about 7 mm). In the illustrated embodiment, the second base material 208 includes a plurality of tobacco rods formed in a substantially cylindrical portion. Similarly, in various embodiments, the size and shape of the second base material 108 can vary. For example, in some embodiments, the second base material 208 can have a length in the inclusive range of about 5 mm to about 25 mm and an overall diameter in the inclusive range of about 3 mm to about 8 mm. In the illustrated embodiment, the second base material 208 has a length of about 30 mm and a diameter of about 4.8 mm (and in some embodiments, about 7 mm).

[0118] The smoking article of the illustrated embodiment also includes a filter 212. It should be noted that in various embodiments, the smoking article may also include intermediate components such as the above-described intermediate components. In various embodiments, the filter 212 can be regarded as the mouthpiece 214 of the smoking article 200 individually or together with another component. It should be noted that in various embodiments, neither the intermediate component nor the filter needs to be included. However, in the illustrated embodiment, the filter 212 is included to filter the aerosol generated by the base material 206 and / or 208 before being inhaled by the user. In the illustrated embodiment, the filter includes a filled rod or a cylindrical disk made of a gas-permeable material (e.g., cellulose acetate or fibers, such as paper or rayon, or polyester fibers). The filter 112 may additionally or alternatively contain strands of tobacco-containing material as described in U.S. Patent No. 5,025,814 to Raker et al., which is hereby incorporated by reference in its entirety. In various embodiments, the size and shape of the filter 212 can vary. For example, the length of the intermediate component 110 can be in the inclusive range of about 10 mm to about 30 mm, the diameter of the intermediate component 110 can be in the inclusive range of about 3 mm to 8 mm, the length of the filter 112 can be in the inclusive range of about 10 mm to 20 mm, and the diameter of the filter 112 can be in the inclusive range of about 3 mm to 8 mm. In the illustrated embodiment, the filter 112 has a length of about 15 mm and a diameter of about 4.8 mm (and about 7 mm in some embodiments).

[0119] In various embodiments, the mouthpiece 214 (e.g., the filter 212) is configured to receive the generated aerosol in response to the draw applied to the mouthpiece 214 by the user. In some embodiments, the mouthpiece 214 can be engaged to be fixed to a base material (such as the base material 208). For example, adhesives, bonds, welding, etc. may be suitable for engaging the mouthpiece 214 to be fixed to the base material 208. In one example, the mouthpiece 214 is ultrasonically welded and sealed to the second end of the base material 208.

[0120] As described above, in some embodiments, the mouthpiece 214 may include a filter 212 configured to receive an aerosol in response to a draw applied to the mouthpiece 214. In some aspects, the filter 212 is provided as a circular disk disposed radially and / or longitudinally proximate to the second end of the second substrate material 208 in some aspects. In this way, when the mouthpiece 214 is drawn, the filter 212 receives the aerosol flowing through the intermediate component 210 of the smoking article 200.

[0121] Figure 7 shows a schematic cross-sectional view of a heat source and a heat transfer component of a smoking article according to another embodiment of the present disclosure. In particular, Figure 7 shows a heat source 504 and a heat transfer component 505 including a heat transfer cap 507. In various embodiments, the heat source 504 of the illustrated embodiment may be similar to the heat sources described above, and thus, various embodiments of the heat sources described herein are incorporated by reference. In the illustrated embodiment, the heat transfer component 505 includes a solid cylinder extending through the heat source 504. As described above, in other embodiments, the heat transfer component may have other geometric configurations including, for example, a tube, rod, sheet, or mesh. In the illustrated embodiment, the heat transfer component 505 is constructed of aluminum. However, as described above, in other embodiments, the heat transfer component 505 may be constructed of other heat conductive materials including, for example, stainless steel, brass, copper, silver, gold, bronze, graphite, and combinations thereof.

[0122] The embodiment shown in FIG. 7 also includes a heat transfer cap 507 configured to cover an end of a heat source 504 proximate to a substrate material. In the illustrated embodiment, the heat transfer cap 507 includes an end 507A that covers substantially the entire end of the heat source 504 proximate to the substrate material, and a rim portion 507B that extends upwardly and peripherally around at least a portion of the length of the heat source 504. In the illustrated embodiment, the rim portion 507B of the heat transfer cap 507 extends for about 1 / 3 to about 1 / 2 of the length of the heat source 504. In the illustrated embodiment, the heat transfer cap 507 is composed of the same material (e.g., aluminum) as the heat transfer component 505. However, in other embodiments, one or both of the heat transfer component 505 or the heat transfer cap 507 may be constructed of a different material as described above. Further, in various embodiments, one or both of the heat transfer component 505 or the heat transfer cap 507 may be composed of one material (e.g., one conductive material) and coated with another material (e.g., another conductive material).

[0123] In the illustrated embodiment, the heat transfer component 505 extends through a portion of the heat source 504 and penetrates a portion of the first substrate material (see above). In various embodiments, the heat transfer component 505 can extend through any portion of the heat source 504 and can penetrate any portion of the substrate material. In some embodiments, the heat transfer component can further extend into a portion of the second substrate material.

[0124] FIG. 8 shows schematic views of various heat transfer components of a smoking article according to some other embodiments of the present disclosure. In particular, FIG. 8 shows a heat transfer component 275 according to one embodiment of the present disclosure, as well as a heat transfer component 305 according to another embodiment of the present disclosure and a heat transfer component 405 according to yet another exemplary embodiment of the present disclosure. In various embodiments, each of the illustrated heat transfer components 275, 305, 405 is configured to facilitate the transfer of heat from a heat source to one or more downstream substrate materials.

[0125] The heat transfer component 275 of the present disclosure includes a solid cylindrical tube or rod 275A made of a copper material and includes a coating 275B containing an aluminum material. However, it should be noted that in other embodiments, the cylindrical rod 275A and the coating 275B may be made of other materials as described above. The heat transfer component 305 is different in that it includes a sheet 305A made of a copper material and includes a coating 305B containing an aluminum material. However, it should be noted that in other embodiments, as described above, the sheet 305A and the coating 305B may be configured of other materials. For example, in some embodiments, the coating 305B can include a laminated sheet of aluminum on a copper body sheet. Although not shown in the figures, in various embodiments, the heat transfer components 275 and 305 may also include heat transfer caps as described above. In yet other embodiments, the heat transfer component 275 and / or the sheet 305A may be made of an aluminum material and may not include a coating.

[0126] The heat transfer component 405 is different in that it includes a mesh 405A that also includes an aluminum material and includes an extension 405B disposed along the length and containing an aluminum material. It should be noted that in other embodiments, one or both of the mesh 405A or the extension 405B can be constructed of a different material as described above. In the illustrated embodiment, the mesh 405A has a substantially cylindrical shape (e.g., has a circular cross-section), but in various other embodiments, the mesh 405A can have other geometric configurations (e.g., a substantially square, substantially rectangular, or substantially triangular cross-section). Similarly, in the illustrated embodiment, the extension 405B has a disk shape, but in various other embodiments, the extension 405B can have a different shape (e.g., a substantially square or substantially triangular shape, etc.). Further, in various embodiments, the heat transfer component 405 can be configured such that the extension 405B has an arbitrary location along the heat source 204 and / or the substrate material 206. However, in the illustrated embodiment, the extension 405B is configured to be disposed between the heat source 204 and the substrate material 206.

[0127] Figure 9 shows a schematic longitudinal cross - section of a smoking article 700 according to another embodiment of the present disclosure. In particular, Figure 9 shows a smoking article 700 including a heat source 704, a heat transfer component 705, a first inhalable material medium 706, a second inhalable material medium 708, an intermediate component 710, and a filter 712. In the illustrated embodiment, the intermediate component 710 and the filter 712 together form a mouthpiece 714. Also, the smoking article 700 of the illustrated embodiment includes a passage 717 formed through the heat source 704 and through which the hollow structure of the heat transfer component 705 passes. As shown in the figure, in addition to the outer wrapper 702, the depicted embodiment also includes a liner 718 configured to surround at least a portion of the first base material 706 and the heat source 704. Also, as shown in the figure, the outer wrapper 702 (and, optionally, the liner 718 and the first base material 706) may include one or more openings 720 formed such that air enters when the mouthpiece 714 is drawn in. One or more separate cooling openings 721 may also be formed in the outer wrapper 702 in a region proximate to the filter 712.

[0128] In many respects, the embodiment of Figure 9 is similar to the embodiment of Figure 3, and thus the above description regarding the various possible components of the smoking article is referred to. One way in which the embodiment of Figure 9 differs from that of Figure 3 is that the first base material 706 has an extruded hollow shape including a passage 707 formed therethrough. In the illustrated embodiment, the diameter of the first base material passage 707 is substantially the same as the passage 717 formed through the heat source 704, but it should be noted that in various other embodiments, the diameter of the passage 707 may vary. Thus, in some embodiments, the diameter of the first base material passage 707 may be smaller than the diameter of the passage 717 formed through the heat source 704, and in other embodiments, the diameter of the first base material passage 707 may be longer than the diameter of the passage 717 formed through the heat source 704.

[0129] FIG. 10 shows a schematic longitudinal cross - sectional view of a smoking article 800 according to another embodiment of the present disclosure. In particular, FIG. 10 shows a smoking article 800 that includes a heat source 804, a heat transfer component 805, a first inhalable material medium 806, an intermediate component 810, and a filter 812. In the illustrated embodiment, the intermediate component 810 and the filter 812 together form a mouthpiece 814. Also, the smoking article 800 of the illustrated embodiment includes a passage 817 that is formed through the heat source 804 and through which the hollow structure of the heat transfer component 805 passes. As shown in the figure, in addition to the outer wrapper 802, the depicted embodiment also includes a liner 818 configured to surround at least a portion of the first base material 806 and the heat source 804. Also, as shown in the figure, the outer wrapper 802 (and, optionally, the liner 818 and the first base material 806) may include one or more openings 820 formed such that air enters when the mouthpiece 814 is drawn on. One or more separate cooling openings 821 may also be formed in the outer wrapper 702 in a region proximate to the filter 812.

[0130] In many respects, the embodiment of FIG. 10 is similar to the embodiment of FIG. 3, and thus reference is made to the above description regarding the various possible components of a smoking article. One way in which the embodiment of FIG. 10 differs from that of FIG. 3 is that the first base material 806 has an extruded hollow shape that includes a passage 807 formed therethrough. In the illustrated embodiment, the diameter of the first base material passage 807 is substantially the same as the passage 817 formed through the heat source 804, but it should be noted that in various other embodiments, the diameter of the passage 807 can vary. Thus, in some embodiments, the diameter of the first base material passage 807 may be smaller than the diameter of the passage 817 formed through the heat source 804, and in other embodiments, the diameter of the first base material passage 807 may be longer than the diameter of the passage 817 formed through the heat source 804.

[0131] Another way in which the embodiment of FIG. 10 differs from the embodiment of FIG. 3 is that the embodiment of FIG. 10 does not include a second base material. Thus, in some embodiments, the length of the first base material 806 and / or the length of the intermediate component 810 can be longer if it is desired to provide a smoking article of the same overall length. In the illustrated embodiment, the length of the intermediate component 810 has been increased to compensate for the absence of the second base material.

[0132] FIG. 11 shows a schematic longitudinal cross - sectional view of a smoking article 900 according to another embodiment of the present disclosure. In particular, FIG. 11 shows a smoking article 900 including a heat source 904, a heat transfer component 905, a first inhalable material medium 906, a second inhalable material medium 908, an intermediate component 910, and a filter 912. In the illustrated embodiment, the intermediate component 910 and the filter 912 together form a mouthpiece 914. Also, the smoking article 900 of the illustrated embodiment includes a passage 917 that is formed through the heat source 904 and through which the hollow structure of the heat transfer component 905 passes. As shown in the figure, in addition to the outer wrapper 902, the depicted embodiment also includes a liner 918 configured to surround at least a portion of the first base material 906 and the heat source 904. As also shown in the figure, the outer wrapper 902 (and optionally the liner 918 and the first base material 906) may include one or more openings 920 formed such that air enters when the mouthpiece 914 is drawn on. One or more separate cooling openings 921 may also be formed in the outer wrapper in a region proximate to the filter 712.

[0133] In many respects, the embodiment of FIG. 11 is similar to the embodiment of FIG. 3, and thus the above description regarding the various possible components of a smoking article is referred to. One way in which the embodiment of FIG. 11 differs from that of FIG. 3 is that the hollow structure of the heat transfer component 905 extends at least partially into the first base material 906 beyond the distal flange. In other embodiments, the hollow structure of the heat transfer component 905 can extend through the first base material 906 and into the second base material 908.

[0134] Smoking articles according to the present disclosure can take various embodiments, as discussed in detail herein, but the scope of use of the smoking articles by consumers is the same. The foregoing description of using the smoking articles can be applied to the various embodiments described through minor modifications. The embodiments will be apparent to those skilled in the art in light of the further disclosure provided herein. However, the description of use is not intended to limit the use of the articles of the present invention, but is presented to meet all the necessary requirements disclosed herein.

[0135] Many modifications and other embodiments of the present disclosure will come to mind to those skilled in the art to which this disclosure pertains, having the benefit of the teachings presented in the foregoing description and the related drawings. Accordingly, it is to be understood that the present disclosure should not be limited to the specific embodiments disclosed herein, but that modified forms and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are used herein, they are used only in a general and descriptive sense and not for purposes of limitation.

Claims

1. A heat source, A base material having opposing first and second ends, wherein the heat source is disposed proximate to the first end of the base material, and the base material has an associated aerosol precursor composition, the base material, A mouthpiece disposed proximate to the second end of the base material, and A smoking article comprising a heat transfer component including a hollow structure and opposing first and second flanges disposed at respective ends, the first and second flanges being attached to the hollow structure, The smoking article, wherein the hollow structure of the heat transfer component extends through a passage of the heat source and the hollow structure is configured to allow passage of air.

2. The smoking article according to claim 1, wherein the base material includes at least one of tobacco-containing beads, tobacco shreds, tobacco strips, fragments of reconstituted tobacco material, tobacco rods, and non-tobacco materials.

3. The smoking article according to claim 1, further comprising one or more perforations disposed in the base material, the perforations being configured to facilitate air flow through the smoking article.

4. The smoking article according to claim 1, further comprising a second base material having opposing first and second ends, the second base material being disposed between the first base material and the mouthpiece.

5. The smoking article according to claim 4, wherein the second base material includes at least one of tobacco-containing beads, tobacco shreds, tobacco strips, fragments of reconstituted tobacco material, and tobacco rods.

6. The smoking article according to claim 1, wherein the mouthpiece includes an intermediate component.

7. The smoking article according to claim 1, wherein the mouthpiece includes a filter.

8. The smoking article according to claim 1, wherein the heat source is configured to generate heat upon ignition.

9. The smoking article according to claim 8, wherein the heat source includes an extruded monolithic carbonaceous material.

10. The smoking article according to claim 9, wherein the extruded monolithic carbonaceous material defines one or more grooves extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material.

11. The smoking article according to claim 1, wherein the base material includes a series of overlapping layers of an initial base sheet.

12. A heat source, A base material having opposing first and second ends, wherein the heat source is disposed proximate to the first end of the base material, and the base material has an associated aerosol precursor composition, the base material A mouthpiece disposed proximate to the second end of the base material, and A heat transfer component A smoking article comprising The heat transfer component extends from the heat source, penetrates at least a portion of the base material, and the heat transfer component includes a cap disposed between the heat source and the base material, the smoking article.

13. The smoking article according to claim 12, wherein the heat transfer component includes one or more closed-end structures.

14. The smoking article according to claim 13, wherein the one or more closed-end structures are composed of at least one of aluminum and copper having an aluminum coating.

15. The smoking article according to claim 12, wherein the heat transfer component includes one or more solid rods.

16. The smoking article according to claim 12, wherein the one or more solid rods are composed of at least one of aluminum and copper having an aluminum coating.

17. The smoking article according to claim 12, wherein the heat transfer component includes an aluminum mesh.

18. The smoking article according to claim 17, wherein the heat transfer component further includes an aluminum disk disposed at a position along the length of the aluminum mesh.

19. The smoking article according to claim 12, wherein the heat transfer component includes one or more solid sheets.

20. The smoking article according to claim 19, wherein the one or more solid sheets are composed of at least one of aluminum and copper having an aluminum coating.

21. The smoking article according to claim 12, wherein the base material includes at least one of tobacco-containing beads, tobacco flakes, tobacco strips, fragments of reconstituted tobacco material, or tobacco rods.

22. The smoking article according to claim 12, further comprising a second base material having opposing first and second ends, and the second base material is disposed between the first base material and the mouthpiece.

23. The smoking article according to claim 22, wherein the second base material includes at least one of tobacco-containing beads, tobacco flakes, tobacco strips, fragments of reconstituted tobacco material, and tobacco rods.

24. The smoking article according to claim 12, wherein the mouthpiece comprises an intermediate component.

25. The smoking article according to claim 12, wherein the mouthpiece comprises a filter.

26. The smoking article according to claim 12, wherein the heat source is configured to generate heat when ignited.

27. The smoking article according to claim 26, wherein the heat source comprises an extruded monolithic carbonaceous material.

28. The smoking article according to claim 27, wherein the extruded monolithic carbonaceous material defines one or more grooves extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material.

29. The smoking article according to claim 12, wherein the base material comprises a series of overlapping layers of an initial base sheet.

30. The smoking article according to claim 1, wherein the first and second flanges are composed of the same material.

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