Smoking products with removable cartridges

Abstract

To provide a smoking article that comprises a holder and a removable cartridge.SOLUTION: A cartridge is configured to be received at a receiving end of a holder, and comprises a heat source configured to generate heat, and a substrate portion comprising a substrate material having an aerosol precursor composition coupled therewith. The holder comprises an ejection mechanism configured to move the cartridge relative to the holder between a received position and an ejected position. In one implementation, the ejection mechanism comprises a pusher pin, a guide ring, a carrier sleeve, and a spring, where the cartridge is configured to be received in the carrier sleeve, and where the pusher pin is configured to move relative to the guide ring so as to actuate the carrier sleeve alternately between the received position and the ejected position.SELECTED DRAWING: Figure 5

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 generation of an aerosol (e.g., smoking articles for obtaining components of tobacco, tobacco extracts, nicotine, synthetic nicotine, non-nicotine flavorings, and other materials in an inhalable form, commonly referred to as heat-not-burn systems or e-cigarettes). The components of such articles can be made from or derived from tobacco, or these articles can otherwise feature tobacco incorporated for human consumption, and the components of tobacco and / or other tobacco-related materials can be vaporized to form an inhalable aerosol for human consumption. [Background technology]

[0002] Many smoking articles have been proposed over the years as improvements or replacements for smoking products based on tobacco combustion. Exemplary replacements include devices in which a solid or liquid fuel is burned to transfer heat to the tobacco, or devices in which a chemical reaction is used to provide such a heat source. Examples include the smoking articles described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference.

[0003] The gist of the improvement or replacement of smoking article is typically to provide the sensation associated with smoking cigarettes, cigars or pipes without delivering a significant amount of incomplete combustion and pyrolysis products.For this purpose, many smoking products, flavor generators and medicinal inhalers have been proposed, which utilize electrical energy to vaporize or heat volatile materials, or to provide the sensation of smoking cigarettes, cigars or pipes without significantly burning tobacco.For example, see the various alternative smoking articles, aerosol delivery devices and heat sources described in the background art of Robinson et al., U.S. Patent No. 7,726,320, and Griffith, Jr. et al., U.S. Patent Application Publication No. 2013 / 0255702 and Sears et al., U.S. Patent Application Publication No. 2014 / 0096781, which are incorporated herein by reference. See also, for example, the various types of smoking articles, aerosol delivery devices, and electrically powered heating sources referenced by trade names and commercial sources described in U.S. Patent Application Publication No. 2015 / 0220232 to Bless et al., which is incorporated herein by reference. Additional types of smoking articles, aerosol delivery devices, and electrically powered heating sources referenced by trade names and commercial sources are described in U.S. Patent Application Publication No. 2015 / 0245659 to DePiano et al., which is also incorporated herein by reference in its entirety.Other representative cigarettes or smoking articles that have been described, and in some cases are commercially available, include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al., U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,249,586 to Counts et al., U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,249,586 to Counts et al., U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,060,671 ... No. 5,388,594 to Higgins et al., U.S. Pat. No. 5,666,977 to Adams et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513, No. 253 to Robinson et al., U.S. Pat. No. 7,726,320 to Hamano, U.S. Pat. No. 7,896,006 to Shayan, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. App. Pub. Nos. 2009 / 0095311 to Hon, U.S. Pat. App. Pub. Nos. 2006 / 0196518 to Hon, U.S. Pat. App. Pub. Nos. 2009 / 0126745 and 2009 / 0188490 to Thorens et al. U.S. Patent Application Publication No. 2009 / 0272379, U.S. Patent Application Publication Nos. 2009 / 0260641 and 2009 / 0260642 to Monsees et al., U.S. Patent Application Publication Nos. 2008 / 0149118 and 2010 / 0024834 to Oglesby et al., U.S. Patent Application Publication No. 2010 / 0307518 to Wang, and WO 2010 / 091593 to Hon.

[0004] Various modes and methods have been proposed for assembling smoking articles having a plurality of sequentially arranged segmented components. See, 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., as well as the various types of assembly techniques and methods described in U.S. Patent Application Publication Nos. 2010 / 0186757 to Crooks et al., 2012 / 0042885 to Stone et al., and 2012 / 00673620 to Conner et al., each of which is incorporated herein by reference in its entirety.

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

[0006] Conventional smoking articles, such as those referenced above, can be difficult to assemble due to the multiple components that must be disassembled and reassembled upon ingestion of the aerosol-delivery components provided therein. In other examples, some smoking articles, particularly those using conventional paper wrapping materials, are also prone to scorching the paper wrapping material covering the ignitable fuel source due to the high temperatures achieved by the fuel source in close proximity to the paper wrapping material. This can reduce the enjoyment of some consumers' smoking experience and can mask or undesirably alter the flavor delivered to the consumer by the aerosol-delivery components of the smoking article. In a further example, conventional smoking articles can produce relatively significant levels of gases, such as carbon monoxide and / or carbon dioxide, during use (e.g., as products of carbon combustion). In yet another example, conventional smoking articles can suffer from poor performance with regard to aerosolizing aerosol-forming components. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] U.S. Patent No. 9,078,473 [Patent Document 2] U.S. Patent No. 7,726,320 [Patent Document 3] US Patent Application Publication No. 2013 / 0255702 [Patent Document 4] US Patent Application Publication No. 2014 / 0096781 [Patent Document 5] US Patent Application Publication No. 2015 / 0220232 [Patent Document 6] US Patent Application Publication No. 2015 / 0245659 [Patent Document 7] U.S. Patent No. 4,735,217 [Patent Document 8] U.S. Patent No. 4,922,901 [Patent Document 9] U.S. Patent No. 4,947,874 [Patent Document 10] U.S. Patent No. 4,947,875 [Patent Document 11] U.S. Patent No. 5,060,671 [Patent Document 12] U.S. Patent No. 5,249,586 [Patent Document 13] U.S. Patent No. 5,388,594 [Patent Document 14] U.S. Patent No. 5,666,977 [Patent Document 15] U.S. Patent No. 6,053,176 [Patent Document 16] U.S. Patent No. 6,164,287 [Patent Document 17] U.S. Patent No. 6,196,218 [Patent Document 18] U.S. Patent No. 6,810,883 [Patent Document 19] U.S. Patent No. 6,854,461 [Patent Document 20] U.S. Patent No. 7,832,410 [Patent Document 21] U.S. Patent No. 7,513,253 [Patent Document 22] U.S. Patent No. 7,896,006 [Patent Document 23] U.S. Patent No. 6,772,756 [Patent Document 24] US Patent Application Publication No. 2009 / 0095311 [Patent Document 25] US Patent Application Publication No. 2006 / 0196518 [Patent Document 26] US Patent Application Publication No. 2009 / 0126745 [Patent Document 27] US Patent Application Publication No. 2009 / 0188490 [Patent Document 28] US Patent Application Publication No. 2009 / 0272379 [Patent Document 29] US Patent Application Publication No. 2009 / 0260641 [Patent Document 30] US Patent Application Publication No. 2009 / 0260642 [Patent Document 31] US Patent Application Publication No. 2008 / 0149118 [Patent Document 32] US Patent Application Publication No. 2010 / 0024834 [Patent Document 33] US Patent Application Publication No. 2010 / 0307518 [Patent Document 34] International Publication No. 2010 / 091593 [Patent Document 35] U.S. Patent No. 5,469,871 [Patent Document 36] U.S. Patent No. 7,647,932 [Patent Document 37] US Patent Application Publication No. 2010 / 0186757 [Patent Document 38] US Patent Application Publication No. 2012 / 0042885 [Patent Document 39] US Patent Application Publication No. 2012 / 00673620 Summary of the Invention [Problem to be solved by the invention]

[0008] It would therefore be desirable to provide a smoking article that addresses one or more of the technical problems sometimes associated with conventional smoking articles, and in particular, it would be desirable to provide a smoking article that is easy to use and provides reusable components. [Means for solving the problem]

[0009] In various embodiments, the present disclosure provides smoking articles and removable cartridges for use with smoking articles. The present disclosure includes, but is not limited to, the following exemplary embodiments:

[0010] Exemplary embodiment 1: A smoking article comprising: a holder including a receiving end and a mouth end; a removable cartridge configured to be received in the receiving end of the holder, the removable cartridge comprising a heat source configured to generate heat when ignited, and a substrate portion having opposing first and second ends, the heat source being positioned proximate to the first end of the substrate portion, the substrate portion comprising a substrate material having an aerosol precursor composition bound thereto; and an ejection mechanism configured to move the cartridge relative to the holder between a receiving position and an ejection position.

[0011] Exemplary embodiment 2: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the cartridge further comprises an outer housing configured to surround at least a portion of the substrate portion.

[0012] Exemplary embodiment 3: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the outer housing includes one or more end openings configured to allow aerosol from the substrate material to pass through.

[0013] Exemplary embodiment 4: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the ejection mechanism comprises a pusher pin, a guide ring, a carrier sleeve, and a spring, the cartridge being configured to be received in the carrier sleeve, and the pusher pin being configured to move the carrier sleeve relative to the guide ring to actuate the carrier sleeve alternately between a receiving position and an ejection position.

[0014] Exemplary embodiment 5: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the carrier sleeve comprises a vapor passage and the pusher pin comprises an inner hole, and the vapor passage and the inner hole are configured to provide a path for aerosol from the substrate material to pass through.

[0015] Exemplary Embodiment 6: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the substrate material comprises at least one of tobacco-containing beads, shredded tobacco, strips of tobacco, reconstituted tobacco material, tobacco rods, and non-tobacco materials.

[0016] Exemplary embodiment 7: A smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the substrate material comprises a non-tobacco material.

[0017] Exemplary Embodiment 8: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the heat source comprises an extruded monolithic carbonaceous material.

[0018] Exemplary embodiment 9: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the heat source defines one or more passages extending longitudinally from a first end of the heat source to an opposing second end of the heat source.

[0019] Exemplary embodiment 10: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the heat source defines one or more circumferential grooves extending longitudinally from a first end of the heat source to an opposing second end of the heat source.

[0020] Exemplary embodiment 11: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the holder comprises a body portion and a mouthpiece at the mouth end of the holder, the mouthpiece being configured to move relative to the body portion.

[0021] Exemplary embodiment 12: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the holder includes a plurality of openings disposed adjacent the receiving end.

[0022] Exemplary embodiment 13: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the holder is constructed from at least one of a ceramic material, a plastic material, and a metal material.

[0023] Exemplary embodiment 14: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the holder includes a thermal indicator configured to indicate the status of the cartridge.

[0024] Exemplary embodiment 15: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the substrate material comprises first and second substrate material segments, the second substrate material segment being positioned adjacent to the second end of the first substrate material segment.

[0025] Exemplary embodiment 16: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the second substrate material segment contains at least one of tobacco-containing beads, shredded tobacco, strips of tobacco, reconstituted tobacco material pieces, or tobacco rods.

[0026] Exemplary Embodiment 17: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the second substrate material segment contains a non-tobacco material.

[0027] Exemplary embodiment 18: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the mouthpiece comprises a filter.

[0028] Exemplary embodiment 19: A smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the cartridge includes one or more retention features configured to retain the cartridge when inserted into the holder.

[0029] Exemplary embodiment 20: The smoking article of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the holder includes one or more complementary retention features.

[0030] Exemplary embodiment 21: A detachable cartridge for use with a smoking article comprising: a heat source configured to generate heat upon ignition thereof; a substrate portion having opposing first and second ends, the heat source being positioned proximate to the first end of the substrate portion, the substrate portion comprising a substrate material having an aerosol precursor composition bound thereto; and an outer housing configured to surround at least a portion of the heat source and the substrate portion, the outer housing having an open end and a closed end, the closed end including one or more end openings configured to allow an aerosol from the substrate material to pass through the detachable cartridge.

[0031] Exemplary Embodiment 22: The cartridge of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the substrate material contains at least one of tobacco-containing beads, shredded tobacco, strips of tobacco, reconstituted tobacco material pieces, tobacco rods, and non-tobacco materials.

[0032] Exemplary embodiment 23: The cartridge of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the substrate material comprises a non-tobacco material.

[0033] Exemplary Embodiment 24: The cartridge of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the heat source comprises an extruded monolithic carbonaceous material.

[0034] Exemplary Embodiment 25: The cartridge of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the heat source defines one or more passages extending longitudinally from a first end of the heat source to an opposing second end of the heat source.

[0035] Exemplary Embodiment 26: The cartridge of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the heat source defines one or more circumferential grooves extending longitudinally from a first end of the heat source to an opposing second end of the heat source.

[0036] Exemplary Embodiment 27: The cartridge of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the substrate material comprises first and second substrate material segments, the second substrate material segment being disposed proximate to the second end of the first substrate material.

[0037] Exemplary Embodiment 28: The cartridge of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the second substrate material segment contains at least one of tobacco-containing beads, tobacco shreds, tobacco strips, reconstituted tobacco material pieces, or tobacco rods.

[0038] Exemplary Embodiment 29: The cartridge of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the second substrate material segment contains a non-tobacco material.

[0039] Exemplary Embodiment 30: The cartridge of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the opening comprises a pair of elongated rounded slots.

[0040] These and other features, aspects and advantages of the present disclosure will become apparent from the following detailed description taken in conjunction with the accompanying drawings, which are briefly described below.

[0041] The present disclosure having been described in general terms above, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. [Brief explanation of the drawings]

[0042] [Figure 1] 1 shows a perspective view of a smoking article including a holder and a removable cartridge according to one embodiment of the present disclosure; [Figure 2] 1 shows a perspective view of a cartridge according to one embodiment of the present disclosure. [Figure 3] 1 shows a longitudinal cross-sectional view of a cartridge according to one embodiment of the present disclosure. [Figure 4] 1 illustrates a perspective view of a holder according to one embodiment of the present disclosure. [Figure 5] 1 illustrates a perspective view of a holder showing various internal components according to one embodiment of the present disclosure. [Figure 6] 1 shows a longitudinal cross-sectional view of a holder according to one embodiment of the present disclosure. [Figure 7] 1 shows a perspective view of various components of an ejection mechanism according to one embodiment of the present disclosure. [Figure 8] 1 shows a perspective view of a smoking article with a removable cartridge received in a holder in a receiving position according to one embodiment of the present disclosure; [Figure 9] 1 shows a longitudinal cross-sectional view of a smoking article with a cartridge received in a holder in a receiving position according to one embodiment of the present disclosure; [Figure 10] 1 shows a perspective view of a smoking article showing a cartridge receiving position and a cartridge ejection position according to one embodiment of the present disclosure; DETAILED DESCRIPTION OF THE INVENTION

[0043] The present disclosure will now be described in more detail with reference to exemplary embodiments thereof. These exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, this 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.

[0044] This disclosure provides a description of articles (and their assembly and / or manufacture) in which a material is heated (preferably without significant combustion of the material) to form an aerosol and / or inhalable substance. Most preferably, such articles are small enough to be considered a "handheld" device. In preferred embodiments, the articles are characterized as smoking articles. As used herein, the term "smoking article" is intended to mean an article and / or device that provides many of the sensations of smoking a cigarette, cigar, or pipe (e.g., the type of inhalation and exhalation, the type of taste or aroma, the organoleptic effect, the physical feel, the mode of use, the visual stimulation such as that provided by a visible aerosol, etc.) without substantially combusting any of the components 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 by-products of tobacco combustion or pyrolysis, but rather that the article or device produces vapor resulting from the volatilization or evaporation of certain components, elements, etc. of the article and / or device (including vapor within an aerosol that is considered a visible aerosol that can be considered to be described as smoky). In preferred embodiments, articles or devices characterized as smoking articles incorporate tobacco and / or tobacco-derived components.

[0045] As mentioned above, the aerosol-generating components of certain preferred aerosol delivery devices can provide many of the sensations (e.g., inhalation and exhalation patterns, types of taste or aroma, sensory stimulating effects, physical feel, mode of use, visual cues such as those provided by a visible aerosol, etc.) of smoking a cigarette, cigar, or pipe used by lighting and burning tobacco (and thus inhaling tobacco smoke) without substantially burning any of its components. For example, a user of an aerosol delivery device according to some exemplary embodiments of the present disclosure can hold and use the component, draw on one end of the component to inhale the aerosol generated by the component, take puffs at selected time intervals, etc., in the same manner as a smoker uses a conventional smoking article.

[0046] The articles or devices of the present disclosure may also be characterized as vapor-producing articles, aerosol delivery articles, or drug delivery articles. Thus, such articles or devices can be configured to provide one or more substances in an inhalable form or state. For example, the inhalable substance is substantially in vapor form (e.g., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance is in aerosol form (e.g., a suspension of fine solid particles or liquid droplets in a gas). For clarity, the term "aerosol" as used herein is meant to include vapors, gases, and aerosols in any form or type suitable for human inhalation, regardless of whether they are visible or in a form that can be considered smoky. In some embodiments, the terms "vapor" and "aerosol" may be interchangeable. Therefore, for simplicity, the terms "vapor" and "aerosol" used to describe the present disclosure are understood to be interchangeable unless otherwise specified.

[0047] When in use, smoking articles of the present disclosure are subject to many of the physical actions of an individual when using a conventional smoking article (e.g., a cigarette, cigar, or pipe that is used by lighting it with a flame and then inhaling the burned and / or combusted tobacco). For example, a user of a smoking article of the present disclosure holds the article as with a conventional smoking article, draws on one end of the article to inhale the aerosol produced by the article, and takes puffs for selected time intervals.

[0048] Although the systems are generally described herein with respect to embodiments related to smoking articles, such as so-called "electronic cigarettes" or "tobacco heating products," it should be understood that the features, components, features, and methods may be embodied in many different forms and associated with a variety of items. For example, the descriptions provided herein can be used in conjunction with traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heated tobacco products, and related packaging embodiments for any of the products disclosed herein. Accordingly, it should be understood that the descriptions of the features, components, features, and methods disclosed herein are discussed by way of example only with respect to embodiments related to aerosol delivery devices, and can be embodied in and used in a variety of other products and methods.

[0049] Smoking articles of the present disclosure generally include a number of elements disposed or housed within some type of enclosure, such as a housing, outer wrap or packaging, casing, component, module, member, etc. The overall design of the enclosure may vary, as may the type or configuration of the enclosure that defines the overall size and shape of the smoking article. In some embodiments, it is desirable for the overall design, size, and / or shape of the enclosure to resemble that of a traditional cigarette or cigar. Typically, a cigarette- or cigar-shaped enclosure comprises separable components, members, etc. that are engaged to form the enclosure. For example, in some embodiments, such a smoking article may include three separable components, including a mouthpiece component, an aerosol delivery component (e.g., a substrate material, etc.), and a heat source component. In various aspects, the heat source is capable of generating heat to aerosolize substrate materials, including, for example, extruded structures and / or substrates in solid or liquid form (e.g., beads, sheets, shreds, wraps), substrate materials combined with an aerosol precursor composition, tobacco and / or tobacco-related materials, e.g., materials isolated directly from tobacco, materials naturally found in tobacco, or synthetically prepared materials. In some embodiments, the extruded structures may comprise tobacco products or composites of tobacco and other materials, such as ceramic powders. In other embodiments, porous ceramic beads may be filled with tobacco extracts / slurries. In other embodiments, non-tobacco products may be used. In some embodiments, porous beads / powder (ceramics) filled with e-liquid may be used. In other embodiments, rods / cylinders made from extruded slurries of ceramic powders and e-liquid may be used.

[0050] According to certain aspects of the present disclosure, it would be advantageous to provide a smoking article that provides easy-to-use and reusable components. FIG. 1 shows a perspective view of such a smoking article according to one embodiment of the present disclosure. In particular, FIG. 1 shows a perspective view of a smoking article 100 including a removable cartridge 102 and a holder 104. The holder 104 includes a body portion 120 and a mouthpiece 122 disposed at the mouth end of the holder 104. As described in further detail below, in the illustrated embodiment, the removable cartridge 102 is configured to be received within a cavity 106 defined on a receiving end of the body portion 120 of the holder 104. FIG. 2 shows a perspective view of the removable cartridge 102 of FIG. 1. In the illustrated embodiment, the removable cartridge 102 includes a heat source 108, a base portion 110, and an outer housing 112 configured to enclose at least a portion of the heat source 108 and the base portion 110.

[0051] It should be noted that, while in the illustrated embodiment, cartridge 102 and holder 104 have a substantially cylindrical shape that mimics the shape of a traditional cigarette, in various other embodiments, either or both of these components (and / or any of their subcomponents, such as body portion 120, mouthpiece 122, or ejection mechanism 126 of holder 104, and / or heat source 108, outer housing 112, or substrate material 116 of cartridge 102) may have a different shape. For example, in some embodiments, either or both of holder 104 or cartridge 102 (and / or any of their subcomponents) may have a substantially rectangular shape, e.g., a substantially rectangular cuboid shape (e.g., similar to a USB flash drive). In other embodiments, either or both of holder 104 or cartridge 102 (and / or any of their subcomponents) may have other handheld shapes. For example, in some embodiments, holder 104 may have a small box shape, various pod mod shapes, or a fob shape.

[0052] In various embodiments, the heat source 108 can be configured to generate heat upon ignition. In the illustrated embodiment, the heat source 108 has a generally cylindrical shape and includes a combustible fuel element incorporating a combustible carbonaceous material. In other embodiments, the heat source 108 may have a different shape, for example, a prismatic shape with a cubic or hexagonal cross-section. The carbonaceous material generally has a high carbon content. Preferred carbonaceous materials are composed primarily of carbon and / or typically have a carbon content of greater than about 60 percent, generally greater than about 70 percent, often greater than about 80 percent, and frequently greater than about 90 percent, on a dry weight basis.

[0053] In some cases, heat source 108 may incorporate elements other than combustible carbonaceous material (e.g., tobacco components such as powdered tobacco or tobacco extract; flavorings; salts such as sodium chloride, potassium chloride, and sodium carbonate; thermostable graphite hollow cylindrical (e.g., tubular) fibers; iron oxide powder; glass filaments; powdered calcium carbonate; alumina granules; an ammonia source such as an ammonia salt; and / or binders such as guar gum, ammonium alginate, and sodium alginate). While the specific dimensions of applicable heat sources can vary, in the illustrated embodiment, heat source 108 has a length in the inclusive range of about 5 mm to about 20 mm, and in some embodiments, may be about 17 mm, and an overall diameter in the inclusive range of about 3 mm to about 8 mm, and in some embodiments, may be about 4.8 mm (and in some embodiments, about 7 mm). In other embodiments, heat sources can be constructed in various ways, but in the illustrated embodiment, heat source 108 is extruded or compounded using crushed or powdered carbonaceous material, forming a mass of about 0.5 g / cm on a dry weight basis. 3 Ultra, often about 0.7 g / cm 3 Ultra-frequently about 1g / cm 3 See, for example, the types of fuel source components, formulations, and designs described in U.S. Patent No. 5,551,451 to Riggs et al. and U.S. Patent No. 7,836,897 to Borschke et al., which are incorporated herein by reference in their entireties.

[0054] Although in various embodiments the heat source may have a variety of forms, including, for example, a substantially solid cylindrical or hollow cylindrical (e.g., tubular) shape, the heat source 108 in the illustrated embodiment comprises an extruded monolithic carbonaceous material having a generally cylindrical shape including a plurality of internal passages 114 extending longitudinally from a first end of the heat source 108 to an opposing second end of the heat source 108. In the illustrated embodiment, there are approximately thirteen internal passages 114 including a single central internal passage 114a, six peripheral internal passages 114b spaced apart from the central internal passage 114a and having a similar size (e.g., diameter) to the central internal passage 114a, and six peripheral internal passages 114c spaced apart from the outer surface of the heat source 108 and having a smaller diameter than the diameter of the central internal passage 114a. It should be noted that in other embodiments, there need not be multiple internal passages and / or the multiple internal passages can take other forms and / or sizes. For example, in some embodiments, there may be as few as two internal passages, while still other embodiments may include as few as one internal passage. Still other embodiments may include no internal passages at all. Additional embodiments may include multiple internal passages that may not be equal in diameter and / or shape and may be unevenly spaced and / or positioned within the heat source.

[0055] Although not shown in the figures, some embodiments may alternatively or additionally include one or more circumferential grooves extending longitudinally from a first end of the heat source to an opposing second end. In some embodiments, such grooves may be substantially equal in width and depth and may be substantially evenly distributed around the circumference of the heat source. In such embodiments, there may be as few as two grooves, and still other embodiments may include as few as one groove. Still other embodiments may not include any grooves at all. Additional embodiments may include multiple grooves that may be unequal in width and / or depth and may be unevenly spaced around the circumference of the heat source. In still other embodiments, the heat source may include flutes and / or slits extending longitudinally from a first end of the extruded monolithic carbonaceous material to its opposing second end. In some embodiments, the heat source may comprise an expanded carbon monolith formed by an expansion process of the type disclosed in U.S. Pat. No. 7,615,184 to Lobovsky, which is incorporated herein by reference in its entirety. Thus, some embodiments may provide advantages in terms of reducing the time it takes to ignite the heat source. In some other embodiments, the heat source is extruded with a layer of insulating material (not shown), thereby reducing manufacturing time and costs. Other fuel element embodiments include carbon fiber of the type described in U.S. Pat. No. 4,922,901 to Brooks et al., or other heat source embodiments such as those disclosed in U.S. Patent Application Publication No. 2009 / 0044818 to Takeuchi et al., each of which is incorporated herein by reference in its entirety. Further examples of heat sources, methods, and smoking articles including debossed heat source systems are disclosed in U.S. Patent Application No. 15 / 902,665, filed February 22, 2018, entitled "System for Debossing a Heat Generation Member, a Smoking Article Including the Debossed Heat Generation Member, and a Related Method," which is incorporated herein by reference in its entirety.

[0056] Generally, a heat source is positioned sufficiently close to an aerosol delivery component (e.g., a substrate portion) having one or more aerosolizable components such that the aerosol formed / volatilized by the application of heat from the heat source to the aerosolizable component (and any flavorings, agents, etc. similarly provided for delivery to the user) is deliverable to the user through the mouthpiece. That is, when the heat source heats the substrate component, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the foregoing terms mean that references to release, releasing, releases, or released can be interpreted to include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol, or a mixture thereof. Furthermore, the selection of various smoking article components can be understood with consideration of commercially available electronic smoking articles, such as the representative products listed in the Background section of this disclosure.

[0057] FIG. 3 shows a longitudinal cross-sectional view of the cartridge 102 of FIG. 1. As shown, the base portion 110 has opposing first and second ends, and the heat source 108 is disposed proximate the first end of the base portion 110. While the dimensions of the various components of the cartridge 102 can vary depending on the needs of a particular application, in the illustrated embodiment, the cartridge 102 may have an overall length in the inclusive range of about 10 mm to about 50 mm and a diameter in the inclusive range of about 3 mm to about 10 mm. Additionally, in the illustrated embodiment, the housing 112 may have a thickness in the inclusive range of about 0.05 mm to 0.5 mm. Furthermore, in the illustrated embodiment, the base portion 110 may have a length in the inclusive range of about 5 mm to 30 mm and a diameter slightly smaller than the diameter of the overall cartridge, for example, a diameter in the inclusive range of about 2.9 mm to about 9.9 mm, to accommodate the thickness of the housing 112.

[0058] In the illustrated embodiment, the substrate portion 110 comprises a substrate material 116 having a single segment, although in other embodiments, the substrate portion 110 may include one or more additional substrate material segments. For example, in some embodiments, the smoking article 100 may further comprise a second substrate material segment (not shown) having opposing first and second ends. In various embodiments, one or more of the substrate materials may include tobacco or tobacco-related materials with an aerosol precursor composition bound thereto. In other embodiments, non-tobacco materials, such as cellulose pulp materials, may be used. In other embodiments, the non-tobacco substrate material may not be a plant-derived material. Other possible compositions, components, and / or additives for use in the substrate material(s) are described in further detail below. It should be noted that the following description should be applicable to any substrate material (e.g., substrate material 116 in the illustrated embodiment) that may be used in the smoking articles described herein.

[0059] Referring also to FIG. 1 , in various embodiments, ignition of the heat source 108 results in aerosolization of the aerosol precursor composition bound to the substrate material 116. In various embodiments, the mouthpiece 122 is configured to receive the generated aerosol therethrough in response to drawing applied to the mouthpiece 122 by a user. As described in further detail below, in some embodiments, the mouthpiece 122 may include a filter configured to receive the aerosol therethrough in response to drawing applied to the mouthpiece 122. In various embodiments, the filter is provided as a circular disk, in some aspects, radially and / or longitudinally disposed adjacent the end of the holder 104 opposite the receiving end. In this manner, upon drawing on the mouthpiece 122, the filter receives the aerosol that flows through the holder 104 of the smoking article 100. Preferably, elements of the substrate material 116 do not significantly thermally decompose (e.g., char, scorch, or burn), and the aerosolized components are entrained in air drawn through the smoking article 100, including the filter (if present), and into the user's mouth. In the illustrated embodiment of the smoking article 100, the substrate material 116 comprises a plurality of tobacco beads formed into a substantially cylindrical section. In some embodiments, the filter may comprise individual segments. For example, some embodiments may include a segment that provides filtration, a segment that provides resistance to draw, a hollow segment that provides space for aerosol to cool, other filter segments, and any one or any combination of the above.

[0060] In one embodiment, the substrate material may comprise a blend of flavorful, aromatic tobaccos in cut filler form. In another embodiment, the substrate material may comprise reconstituted tobacco material, such as those described in U.S. Pat. Nos. 4,807,809 to Pryor et al., 4,889,143 to Pryor et al., and 5,025,814 to Raker, the entire disclosures of which are incorporated herein by reference. Furthermore, the reconstituted tobacco material may comprise reconstituted tobacco paper for cigarettes of the type described in "Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco," R.J. Reynolds Tobacco Company Monograph (1988), the entire contents of which are incorporated herein by reference. For example, the reconstituted tobacco material may comprise a sheet-like material containing tobacco and / or tobacco-related materials. Thus, in some embodiments, the substrate material may be formed from a wound roll of reconstituted tobacco material. In another embodiment, the substrate material may be formed from shreds, strips, or the like of reconstituted tobacco material. In another embodiment, the tobacco sheet may comprise overlapping layers (e.g., gathered webs) that may or may not include a thermally conductive component. An example of a substrate portion comprising a series of overlapping layers (e.g., gathered webs) of an initial substrate sheet formed by a fibrous filler material, an aerosol-forming material, and a plurality of thermally conductive components is described in U.S. Patent Application No. 15 / 905,320, filed February 26, 2018, entitled "Heat Conducting Substrate For Electrically Heated Aerosol Delivery Device," which is incorporated herein by reference in its entirety.

[0061] In some embodiments, the substrate material may include a plurality of microcapsules, beads, granules, and / or the like, having tobacco-related materials. For example, a typical microcapsule may be generally spherical in shape and have an outer cover or shell containing a liquid center region of tobacco-derived extract and / or the like. In some embodiments, one or more of the substrate materials may include a plurality of microcapsules, each formed in a hollow cylindrical shape. In some embodiments, one or more of the substrate materials may include a binder material configured to maintain the structural shape and / or integrity of the plurality of microcapsules formed in a hollow cylindrical shape.

[0062] The tobacco used in one or more of the substrate materials may include or be derived from tobaccos such as flue-cured, burley, Oriental, Maryland, dark, dark-flavored, and rustica tobaccos, as well as other rare or specialty tobaccos, or blends thereof. Various representative tobacco types, tobacco processing types, and tobacco blend types are described in U.S. Patent No. 4,836,224 to Lawson et al., U.S. Patent No. 4,924,888 to Perfetti et al., U.S. Patent No. 5,056,537 to Brown et al., U.S. Patent No. 5,159,942 to Brinkley et al., U.S. Patent No. 5,220,930 to Gentry, U.S. Patent No. 5,360,023 to Blakley et al., U.S. Patent No. 5,360,023 to Shafer et al., the entire disclosures of which are incorporated herein by reference. No. 6,701,936 to Dominguez et al., U.S. Pat. No. 6,730,832 to Dominguez et al., U.S. Pat. No. 7,011,096 to Li et al., U.S. Pat. No. 7,017,585 to Li et al., U.S. Pat. No. 7,025,066 to Lawson et al., U.S. Patent Application Publication No. 2004 / 0255965 to Perfetti et al., PCT Publication No. WO 02 / 37990 to Bereman, and Fund. Appl. Toxicol., 39, pp. 11-17 (1997) to Bombick et al.

[0063] In still other embodiments of the present disclosure, the substrate material may comprise an extruded structure that includes or consists essentially of tobacco, tobacco-related materials, glycerin, water, and / or binder materials, although certain formulations may be binder-free. In various embodiments, suitable binder materials may include alginates such as ammonium alginate, propylene glycol alginate, potassium alginate, and sodium alginate. Alginates, particularly high-viscosity alginates, may be used in combination with controlled levels of free calcium ions. Other suitable binder materials include hydroxypropyl cellulose, such as Klucel H from Aqualon Co.; hydroxypropyl methylcellulose, such as Methocel K4MS from The Dow Chemical Co.; hydroxyethyl cellulose, such as Natrosol 250 MRCS from Aqualon Co.; microcrystalline cellulose, such as Avicel from FMC; methylcellulose, such as Methocel A4M from The Dow Chemical Co.; and sodium carboxymethylcellulose, such as CMC 7HF and CMC 7H4F from Hercules Inc. Still other possible binder materials include starch (e.g., corn starch), guar gum, carrageenan, locust bean gum, pectin, and xanthan gum. In some embodiments, a combination or blend of two or more binder materials may be used. Other examples of binder materials are described, for example, in U.S. Pat. No. 5,101,839 to Jakob et al. and U.S. Pat. No. 4,924,887 to Raker et al., each of which is incorporated herein by reference in its entirety. In some embodiments, the aerosol-forming material may be provided as part of the binder material (e.g., propylene glycol alginate). Additionally, in some embodiments, the binder material may include nanocellulose derived from tobacco or other biomass.

[0064] In some embodiments, the substrate material may comprise an extruded material, as described in U.S. Patent Application Publication No. 2012 / 0042885 to Stone et al., which is incorporated herein by reference in its entirety. In yet another embodiment, the substrate material may comprise an extruded structure and / or substrate formed from marumerized and / or non-marumerized tobacco. Marumerized tobacco is known, for example, from U.S. Patent No. 5,105,831 to Banerjee et al., which is incorporated herein by reference in its entirety. Marumerized tobacco comprises about 20 to about 50 percent (by weight) of a tobacco blend in powder form, along with glycerol (about 20 to about 30 percent by weight), calcium carbonate (generally about 10 to about 60 percent by weight, often about 40 to about 60 percent by weight), and a binder and / or flavoring as described herein. In various embodiments, the extruded material may have one or more longitudinal openings.

[0065] In various embodiments, the substrate material may take on various configurations based on the varying amounts of materials utilized therein. For example, the sample substrate material may contain up to about 98%, up to about 95%, or up to about 90% by weight of tobacco and / or tobacco-related materials. The sample substrate material may also contain up to about 25%, about 20%, or about 15% by weight of water, particularly about 2% to about 25%, about 5% to about 20%, or about 7% to about 15% by weight of water. Flavors and the like (e.g., including agents such as nicotine) can comprise up to about 10%, up to about 8%, or up to about 5% by weight of the aerosol delivery components.

[0066] Additionally or alternatively, the substrate material may comprise an extruded structure and / or substrate that includes or consists essentially of 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 substrate material may be configured to substantially maintain its shape throughout the aerosol generation process (e.g., the substrate material does not continuously deform under applied shear stress). While such exemplary substrate materials may include liquid and / or some moisture content, the substrate may remain substantially solid throughout the aerosol generation process and may substantially maintain its structural integrity throughout the aerosol generation process. Exemplary tobacco and / or tobacco-related materials suitable for the substantially solid substrate material are described in U.S. Patent Application Publication No. 2015 / 0157052 to Ademe et al., U.S. Patent Application Publication No. 2015 / 0335070 to Sears et al., U.S. Patent No. 6,204,287 to White, and U.S. Patent No. 5,060,676 to Hearn et al., which are incorporated by reference in their entireties.

[0067] In some embodiments, the amount of substrate material used in a smoking article can be 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 in the substrate material to generate a visible mainstream aerosol that resembles in many respects the appearance of tobacco smoke. For example, the amount of aerosol precursor composition incorporated into the substrate material of a 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.

[0068] According to another embodiment, a smoking article according to the present disclosure may include a substrate material comprising a porous inert material, such as, for example, a ceramic material. For example, in some embodiments, ceramics of various shapes and configurations (e.g., beads, rods, tubes, etc.) with various pore morphologies may be used. Furthermore, in some embodiments, non-tobacco materials, such as e-liquid, may be loaded into the ceramic. In another embodiment, the substrate material may include a porous inert material that is substantially chemically and / or physically unreactive with tobacco-related materials, such as tobacco-derived extracts. Furthermore, extruded tobacco, such as those described above, may be porous. For example, in some embodiments, the extruded tobacco material may have an inert gas, such as nitrogen, that acts as a foaming agent during the extrusion process.

[0069] As noted above, in some embodiments, one or more of the substrate materials may include tobacco, tobacco components, and / or tobacco-derived materials that have been processed, manufactured, produced, and / or processed to incorporate an aerosol precursor composition (e.g., a humectant, e.g., propylene glycol, glycerin, etc.) and / or at least one flavoring, as well as a flame retardant / flame retardant (e.g., diammonium phosphate and / or another salt) configured to help prevent ignition, thermal decomposition, combustion, and / or charring of the substrate material by a heat source. Various modes and methods for incorporating tobacco into smoking articles, particularly smoking articles designed to intentionally prevent the combustion of substantially any tobacco within the smoking article, are described in U.S. Pat. No. 4,947,874 to Brooks et al., U.S. Pat. No. 7,647,932 to Cantrell et al., U.S. Pat. No. 8,079,371 to Robinson et al., U.S. Pat. No. 7,290,549 to Banerjee et al., and U.S. Patent Application Publication No. 2007 / 0215167 to Crooks et al., the entire disclosures of which are incorporated herein by reference.

[0070] As previously mentioned, in some embodiments, flame-retardant / flame-retardant materials and other additives may be included in one or more of the substrate materials and may include organophosphorus compounds, borax, hydrated alumina, graphite, potassium tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Others, such as nitrogen phosphonates, monoammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ethanolammonium borate, ammonium sulfamate, halogenated organic compounds, thiourea, and antimony oxide, are also suitable but are not preferred agents. In each aspect of the flame-retardant, flame-retardant, and / or char-retardant materials used in the substrate materials and / or other components (whether alone or in combination with each other and / or other materials), the desired properties are most preferably provided without undesirable outgassing or melting behavior.

[0071] According to other embodiments of the present disclosure, the substrate material may also incorporate tobacco additives of the type conventionally used in the manufacture of tobacco products. These additives may include materials of the type used to enhance the flavor and aroma of tobacco used in the manufacture of cigars, cigarettes, pipes, and the like. For example, these additives may include various cigarette casing and / or top dressing ingredients. See, for example, U.S. Patent No. 3,419,015 to Wochnowski, U.S. Patent No. 4,054,145 to Berndt et al., U.S. Patent No. 4,887,619 to Burcham, Jr. et al., U.S. Patent No. 5,022,416 to Watson, U.S. Patent No. 5,103,842 to Strang et al., and U.S. Patent No. 5,711,320 to Martin, the entire disclosures of which are incorporated herein by reference. Preferred casing materials may include water, sugars and syrups (e.g., sucrose, glucose, and high fructose corn syrup), humectants (e.g., glycerin or propylene glycol), and flavorings (e.g., cocoa and licorice). These additional ingredients may also include top dressing materials (e.g., flavorings such as menthol). See, for example, U.S. Pat. No. 4,449,541 to Mays et al., the entire disclosure of which is incorporated herein by reference. Additional materials that can be added include those disclosed in U.S. Pat. No. 4,830,028 to Lawson et al. and U.S. Pat. No. 8,186,360 to Marshall et al., the entire disclosures of which are incorporated herein by reference.

[0072] As noted above, in various embodiments, one or more of the substrate materials can have an aerosol precursor composition bound thereto. For example, in some embodiments, the aerosol precursor composition can comprise one or more different components, such as a polyhydric alcohol (e.g., glycerin, propylene glycol, or mixtures thereof). Representative types of additional aerosol precursor compositions are described in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al., U.S. Pat. No. 5,101,839 to Jakob et al., PCT Publication No. WO 98 / 57556 to Biggs et al., and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R.J. Reynolds Tobacco Company Monograph (1988), the disclosures of which are incorporated herein by reference. In some aspects, the substrate material can generate a visible aerosol upon application of sufficient heat (and, if necessary, cooling with air), and the substrate material can generate a "smoky" aerosol. In other aspects, the substrate material can generate an aerosol that is substantially invisible but whose presence is recognized by other characteristics, such as flavor or texture. Thus, the nature of the aerosol generated can be variable depending on the particular components of the aerosol delivery component. The substrate material can be chemically simple compared to the chemistry of smoke generated by burning tobacco.

[0073] A wide variety of flavorings or materials that alter the sensory or organoleptic characteristics or properties of the mainstream aerosol of a smoking article may be suitable for use. In some embodiments, such flavorings may be provided from sources other than tobacco and may be natural or artificial in nature. For example, some flavorings may be applied to or incorporated into the substrate material and / or the region of the smoking article where the aerosol is generated. In some embodiments, such substances may be provided directly to the heating cavity or region proximate the heat source or provided together with the substrate material. Exemplary flavors may include, for example, vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, and flavor and flavor packages of the type and characteristics conventionally used in cigarette, cigar, and pipe tobacco flavorings. Syrups, such as high fructose corn syrup, may also be suitable for use.

[0074] Flavorings may also contain acidic or basic properties (e.g., organic acids such as levulinic acid, succinic acid, pyruvic acid, and benzoic acid). In some embodiments, flavorings may be combined with components of the substrate material, if desired. Exemplary plant-derived compositions that may be suitable are disclosed in U.S. Pat. No. 9,107,453 and U.S. Patent Application Publication No. 2012 / 0152265, both to Dube et al., the disclosures of which are incorporated herein by reference in their entireties. Any material, such as flavorings, casings, and the like, that is useful in combination with tobacco materials to affect their sensory properties, including those described herein, may be combined with the substrate material. In particular, organic acids may be incorporated into the substrate material to affect the flavor, sensory, or organoleptic properties of agents such as nicotine that may be combined with the substrate material. For example, organic acids such as levulinic acid, lactic acid, and pyruvic acid may be included in the substrate material along with nicotine in amounts up to equimolar with nicotine (based on total organic acid content). Any combination of organic acids may be suitable. For example, in some embodiments, the substrate material may comprise 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 to 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., which is incorporated herein by reference in its entirety.

[0075] The selection of such additional ingredients can vary based on factors such as the sensory characteristics desired in the smoking article, and the present disclosure is intended to encompass any such additional ingredients that would be readily apparent to one skilled in the art of tobacco and tobacco-related or tobacco-derived products. See Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972), the entire disclosures of which are incorporated herein by reference.

[0076] In other embodiments, the substrate material may include other materials with various unique characteristics or properties. For example, the substrate material may include a plasticized material in the form of rayon or regenerated cellulose. As another example, viscose (commercially available as VISIL®), a regenerated cellulose product incorporating silica, may be suitable. Some carbon fibers may contain at least 95 percent carbon or more. Similarly, natural cellulose fibers such as cotton may be suitable, and may be infused with or treated with silica, carbon, or metal particles to enhance flame retardant properties and, in particular, minimize the outgassing of any undesirable outgassing components that would adversely affect flavor (especially minimizing the potential for any harmful outgassing products). For example, cotton could be treated with boric acid or various organophosphate compounds to provide the desired flame retardant properties by dipping, spraying, or other techniques known in the art. These fibers could also be treated (e.g., coated by dipping, spraying, or vapor deposition, impregnated, or both) with organic or metallic nanoparticles to impart desired flame retardant properties without undesirable outgassing or melt-type behavior.

[0077] In the illustrated embodiment, the substrate material 116 may include a longitudinally extending axis defined centrally between opposing first and second ends, and the cross-section of the substrate material 116 may, in some embodiments, be symmetrical about the axis. For example, in some embodiments, the cross-section of the substrate material 116 may be substantially circular, such that the substrate material 116 defines a substantially cylindrical shape extending between its opposing first and second ends. However, in other embodiments, the substrate material 116 may define a substantially non-circular cross-section, such that the substrate material 116 may define a substantially non-cylindrical shape between its opposing first and second ends. Alternatively, in other examples, the substrate material 116 may have an asymmetric cross-section about the axis. In various embodiments, each end of the substrate material 116 may be axially aligned with an adjacent element. For example, in some embodiments, a barrier may exist between the second end of the heat source 108 and the first end of the substrate material 116. In some embodiments, such a barrier may comprise a disk that may include one or more openings therethrough. In some embodiments, the barrier may be constructed from a metallic material (e.g., stainless steel, aluminum, brass, copper, silver, gold, bronze, etc.), or a graphite material, or a ceramic material, or a plastic material, or any combination thereof. In other embodiments, a heat transfer component may be present between the heat source 108 and / or the substrate material 116. Examples of heat transfer components are described in U.S. Patent Application No. 15 / 923,735, filed March 16, 2018, entitled "Smoking Article with Heat Transfer Component," which is incorporated herein by reference in its entirety.

[0078] As shown in FIGS. 2 and 3 , the cartridge 102 in the illustrated embodiment also includes an outer housing 112 configured to enclose at least a portion of the substrate portion 110, which includes the substrate material 116. In the illustrated embodiment, the outer housing 112 is also configured to enclose at least a portion of the heat source 108. The outer housing 112 in the illustrated embodiment is constructed from an aluminum material. However, in other embodiments, the outer housing 112 may be constructed from other materials, including other metallic materials (e.g., stainless steel, aluminum, brass, copper, silver, gold, bronze, etc.), graphite materials, ceramic materials, plastic materials, or any combination thereof. In the illustrated embodiment, the outer housing 112 is constructed as a tubular structure that encapsulates the substrate material 116. However, as noted above, in other embodiments, the outer housing 112 may have other shapes. While the shape of the outer housing 112 can vary, in the illustrated embodiment, the outer housing 112 comprises a tubular structure having an open end and a closed end. The illustrated embodiment of outer housing 112 also includes one or more end openings 118 disposed at the closed end of outer housing 112 that are configured to allow aerosolized vapor (also referred to herein as "vapor" or "aerosol") to pass therethrough. The end openings in the illustrated embodiment are in the form of a pair of elongated, rounded slots. However, in other embodiments, end openings 118 may have any configuration that allows aerosol to pass therethrough.

[0079] FIG. 4 shows a perspective view of the holder 104 of FIG. 1. As noted above, in other embodiments, the holder 104 may have other shapes, but the holder 104 of the illustrated embodiment includes a body portion 120 and a mouthpiece 122, both of which, at least in the illustrated embodiment, are configured to resemble the size, shape, and overall appearance of a conventional cigarette. In particular, the body portion 120 of the illustrated embodiment comprises a substantially cylindrical hollow tube. Similarly, the mouthpiece 122 of the illustrated embodiment comprises a substantially cylindrical hollow tube having an overall diameter larger than that of the body portion 120. As described in further detail below, the mouthpiece 122 of the illustrated embodiment is configured to be moved (e.g., depressed) relative to the body portion 120 to move the cartridge 102 relative to the holder 104 between the receiving position and the ejection position. For example, in the illustrated embodiment, the inner diameter of the mouthpiece 122 may be slightly larger than or substantially the same as the outer diameter of the body portion 120, allowing for sliding movement between these components. It should be noted that in other embodiments, body portion 120 and / or mouthpiece 122 may have any other configuration. In the illustrated embodiment, mouthpiece 122 has an overall length in the inclusive range of about 10 mm to about 42 mm, and holder has an overall length in the inclusive range of about 83 mm to about 120 mm and a circumference in the inclusive range of about 20 mm to about 40 mm (e.g., a diameter in the inclusive range of about 6 mm to about 13 mm).

[0080] In various embodiments, the body portion 104 and / or the mouthpiece 122 may be constructed from a metallic material (e.g., stainless steel, aluminum, brass, copper, silver, gold, bronze, etc.), a graphite material, a ceramic material, a plastic material, or any combination thereof. Other materials are also possible. As shown in the figures, the holder 104 of the illustrated embodiment also includes a plurality of end openings 124 extending therethrough and configured to align with at least a portion of the heat source 108 when the cartridge 102 is in the receiving position. In this manner, the end openings 124 are configured to provide sufficient airflow to the heat source 108 to keep it ignited when it is in the receiving position. While in various embodiments, such openings may have many different configurations (e.g., including slots and / or rings instead of or in addition to holes), in the illustrated embodiment, the end openings comprise an alternating pattern of substantially circular holes extending around the circumference of the receiving end of the holder 104. In particular, the alternating pattern in the illustrated embodiment includes a first pattern 124a of four longitudinally spaced holes repeated at approximately 90° intervals around the circumference of the receiving end of body portion 120 of holder 104, and a second pattern 124b of three longitudinally spaced holes also repeated at approximately 90° intervals but offset from the first pattern by approximately 45° around the circumference of the end of body portion 120.

[0081] 5 and 6 illustrate various internal components of the holder 104 of FIG. 1 . In particular, the holder 104 of the illustrated embodiment includes various internal components that together provide an ejection mechanism 126 configured to move between an ejection position and a receiving position, e.g., to receive and eject the cartridge 102. In the receiving position of the illustrated embodiment, the cartridge 102 is substantially contained within the body portion 120 of the holder 104, although other embodiments may differ (e.g., embodiments in which at least a portion of the cartridge extends from the holder in the receiving position). At least a portion of the cartridge 102 extends beyond the receiving end of the holder 104 while in the ejection position of the illustrated embodiment. The ejection mechanism of various embodiments can take various forms, such as, for example, an ejection mechanism that ejects the cartridge using a turning / screw mechanism and / or a ratchet mechanism. Other possible ejection mechanisms include mechanisms similar to those used in retractable click pens, e.g., spring-loaded mechanisms and / or various spring-loaded cam mechanisms. The ejection mechanism 126 of the illustrated embodiment is configured to eject the cartridge using a click-in / click-out type cam mechanism. In particular, the ejection mechanism 126 of the illustrated embodiment includes a pusher pin 128, a retaining ring 129, a guide ring 130, a carrier sleeve 132, a spring 134, and a spring seat 136. While the components of the ejection mechanism can be made from a variety of different materials in various embodiments, in the illustrated embodiment, the pusher pin 128, carrier sleeve 132, guide ring 130, and retaining ring 129 are constructed from molded plastic, such as acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate, polyamide (nylon), high-impact polystyrene, polypropylene, and combinations thereof.

[0082] The spring seat 136 in the illustrated embodiment is disposed inside and along the length of the main portion 120 of the holder 104 and is configured to remain fixed relative to the body portion 120. In the illustrated embodiment, the spring seat 136 comprises a separate ring structure configured to be press-fit inside the body portion 120 of the holder 104. However, in other embodiments, the spring seat 134 may be integral with and / or comprise the same part as the body portion 120. In the illustrated embodiment, the spring seat 134 is constructed from an aluminum material, but in other embodiments, the spring seat can be constructed from other materials, including other metallic materials (e.g., stainless steel, brass, copper, silver, gold, bronze, etc.), graphite materials, ceramic materials, plastic materials, or any combination thereof. Other materials are possible.

[0083] 6 , the carrier sleeve 132 in the illustrated embodiment includes a receiving cavity 138 and a vapor passageway 140. In the illustrated embodiment, the receiving cavity 138 is configured to receive the end of the cartridge 102 facing the heat source 108 and retain the cartridge 102 therein during use. The vapor passageway 140 of the carrier sleeve 132 is configured to allow aerosol generated by the substrate material 116 to pass through the carrier sleeve 132. As shown, a portion of the carrier sleeve 132 is configured to be disposed within the inner bore 142 of the pusher pin 128. In this manner, the vapor passageway 140 of the carrier sleeve 132 and the inner bore 142 of the pusher pin 128 are substantially collinear to provide a path for the aerosol to travel after being aerosolized. In some embodiments, at least a portion of the inner bore 142 of the pusher pin 128 may include a filter (not shown), for example, proximate the user side of the mouthpiece 122. In various embodiments, a filter may be included to filter the aerosol generated by the substrate material 116 before it is inhaled by the user. In various embodiments, such a filter may comprise a filler rod or cylindrical disk constructed from a gas-permeable material (e.g., cellulose acetate or polylactic acid (PLA), polyvinyl alcohol (PVOH), or polypropylene fibers such as paper or rayon, or polyester fibers, or various combinations thereof). The filter may additionally or alternatively contain strands of tobacco-containing material, such as those described in U.S. Pat. No. 5,025,814 to Raker et al., which is incorporated herein by reference in its entirety. In various embodiments, the size and shape of the filter can vary.

[0084] In some embodiments, the smoking article may also include an intermediate component between the substrate portion 110 and the filter 112. Note that in various embodiments, the intermediate component or the filter, individually or together, may be considered the filter of the smoking article. In various embodiments, neither the intermediate component nor the filter need be included. In some embodiments, the intermediate component may comprise a substantially rigid member that is substantially inflexible along its longitudinal axis. In some embodiments, the intermediate component may comprise a hollow tubular structure and may be provided for cooling the generated aerosol. In some embodiments, the intermediate component may be usable as a container for collecting the aerosol. In various embodiments, such a tube may be constructed from any of a variety of materials and may include one or more adhesives. Exemplary materials include, but are not limited to, paper, paper layers, paperboard, plastic, cardboard, and / or composite materials. In some embodiments, the intermediate component may comprise a hollow cylindrical element constructed from paper or a plastic material (e.g., ethyl vinyl acetate (EVA), or other polymeric material such as polyethylene, polyester, silicone, or ceramic (e.g., silicon carbide, alumina, etc.), or other acetate fibers, etc.), and the filter comprises a packed rod or cylindrical disk constructed from a gas permeable material (e.g., cellulose acetate or fiber such as paper or rayon, or polyester fiber, etc.).

[0085] In the illustrated embodiment, one end of the spring 134 of the ejection mechanism 126 is configured to contact the spring seat 136, and the other end of the spring 134 is configured to contact the end of the carrier sleeve 132. As described in further detail below, the carrier sleeve 132 is configured to move relative to the body portion 120 of the holder 104 between a receiving position (as shown) and an ejection position. Because the spring seat 136 is mounted inside the body portion 120, during operation, the carrier sleeve 132 is configured to further compress the spring 134 in a direction toward the receiving end of the holder 104 to reach the ejection position. In the illustrated embodiment, the spring 134 is mounted in a semi-compressed state, so that the spring 134 is configured to bias the carrier sleeve 132 in a direction away from the spring seat 136. In particular, in the receiving position, the spring 134, like the spring seat 136, is configured to bias the carrier sleeve 132 against the guide ring 130, which is fixed relative to the body portion 120 of the holder 104.

[0086] As described above, the mouthpiece 122 in the illustrated embodiment is configured to move relative to the body portion 120 when actuated by a user. Additionally, the pusher pin 128 in the illustrated embodiment is configured to be attached to the mouthpiece 122 such that the pusher pin 128 does not move relative to the mouthpiece 122. Thus, the mouthpiece 122 and the pusher pin 128 in the illustrated embodiment are configured to move together relative to the body portion 120 of the holder 104. For example, in the illustrated embodiment, the mouthpiece 122 is press-fit onto the end of the pusher pin 128. However, in other embodiments, these components may be attached in other ways, including with adhesives and / or ultrasonic welding. In still other embodiments, the mouthpiece 122 and the pusher pin 128 may be integral and / or comprise the same part. As described in more detail below, the mouthpiece 122 and the pusher pin 128 are configured to move the carrier sleeve 132 such that the carrier sleeve 132 (and the inserted cartridge 102) alternates between a receiving position and an ejection position.

[0087] FIG. 7 shows a perspective view of various components of the ejection mechanism 126 of FIG. 6. In particular, FIG. 7 shows the spring seat 136, the spring 134, the carrier sleeve 132, the guide ring 130, the pusher pin 128, and the retaining ring 129. The carrier sleeve 132 of the illustrated embodiment includes a first tube portion 144 and a second tube portion 146 extending from the first tube portion 144. In the illustrated embodiment, the second tube portion 146 has an outer diameter that is smaller than the outer diameter of the first tube portion 144. Additionally, the carrier sleeve 132 includes four longitudinal fins 148 that are substantially equally spaced around the circumference of the second tube portion 146. Each of the fins 148 of the illustrated embodiment includes an angled end 150. The guide ring 130 of the illustrated embodiment includes eight internal grooves 152 extending from a first end thereof and four angled stops 154 on the opposite end of the guide ring 130. The pusher pin 128 includes a main portion 156 having a substantially cylindrical tubular shape. A stop flange 158 having a ring shape is defined along the length of the main portion 156. The main portion 156 also includes eight protruding guide features 160 substantially equally spaced around the circumference of the main portion 156 and configured to slide within the internal grooves 152 of the guide ring 130. The end of the main portion 156 includes a series of angled teeth 162. The stop flanges 158 of the pusher pin 128 are disposed on the spring side of the retaining ring 129, and the stop flanges 158 of the pusher pin 128 are fixed relative to the mouthpiece 122, as described above. The inner diameter of the retaining ring 129 and the outer diameter of the main portion 156 of the pusher pin 128 are configured to allow the main portion 156 of the pusher pin 128 to slide within the retaining ring 129. In some embodiments, the retaining ring can act as a stop for the stop flange 158 of the pusher pin 128.

[0088] 5 and 6, in operation, the angled teeth 162 of the pusher pin 128 are configured to engage the angled ends 150 of the longitudinal fins 148 of the carrier sleeve 132 to move the carrier sleeve 132 to the ejection position. In particular, a user may achieve the ejection position by starting from the receiving position (shown in FIGS. 5 and 6) in which the first tube portion 144 of the carrier sleeve 132 abuts the guide ring 130 and the longitudinal fins 148 of the carrier sleeve 132 and the guide features 160 of the pusher pin 128 are disposed within the internal grooves 152 of the guide ring 130, and pushing the mouthpiece 122 toward the receiving end of the holder 104. Because pusher pin 128 is attached to mouthpiece 122 and guide ring 130 is attached to body portion 120 of holder 104, this movement moves guide features 160 of pusher pin 128 into internal grooves 152 of guide ring 130, while teeth 162 of pusher pin 128 press longitudinal fins 148 of carrier sleeve 132 longitudinally of the receiving end of holder 104 within internal grooves 152 of guide ring 130. This movement is resisted by the spring force generated by spring 134, because spring 134 is trapped between the end of carrier sleeve 132 and spring seat 136 (attached to body portion 120 of holder 104).

[0089] Due to the shape and spacing of the components, the guide features 160 of the pusher pins 128 remain inside the internal grooves 152 of the guide ring 130 as the carrier sleeve 132 moves between the receiving and ejecting positions. However, the longitudinal fins 148 of the carrier sleeve 132 are configured to temporarily disengage from the internal grooves 152 of the guide ring 130 so as to rotate a portion of a turn as the carrier sleeve 132 is moved between the receiving and ejecting positions (and vice versa). In particular, as the carrier sleeve 132 is moved from the receiving position by the pusher pins 128, the longitudinal fins 148 slide within the internal grooves 152 of the guide ring 130 until the angled ends 150 of the longitudinal fins 148 move beyond the ends of the internal grooves 152, at which point the angled ends 150 slide along the surfaces of the angled stops 154, causing the carrier sleeve 132 to rotate and begin to move a short distance in the opposite longitudinal direction (e.g., away from the receiving end of the holder 104). Due to the force exerted by the springs 134 against the ends of the carrier sleeve 132, the angled ends 150 of the longitudinal fins 148 continue to slide along the surfaces of the angled stops 154 (and the carrier sleeve 132 continues to rotate) until the angled ends 150 of the longitudinal fins 148 are fully seated within the respective angled stops 154 of the guide ring 130 and the carrier sleeve 132 stops rotating. This position represents the ejection position in which the springs 134 are further compressed from their initial compression in the receiving position and the end of the cartridge 102 bearing the heat source 108 (once the cartridge 102 is received in the first tube portion 144 of the carrier sleeve 132) extends beyond the receiving end of the holder 104. Due to the shape of the angled stops 154 of the guide ring 130, the ejection mechanism 126 is configured to remain in the ejection position until the user again pushes the mouthpiece 122 to move it into the receiving position. Similarly, once ejection mechanism 126 is in the receiving position, it is configured to remain in the receiving position until the user presses mouthpiece 122 to move it to the ejection position.

[0090] Starting from the ejection position, where the angled ends 150 of the longitudinal fins 148 are fully disposed within the angled stops 154 of the guide ring 130, a user may move the ejection mechanism 126 from the ejection position to the receiving position by pushing the mouthpiece 122 toward the receiving end of the holder 104. This causes the pusher pin 128 to move the angled ends 150 of the longitudinal fins 148 a short distance toward the receiving end of the holder 104 and out of full engagement with the angled stops 152 of the guide ring 130. In particular, as the carrier sleeve 132 is moved from the ejection position, the longitudinal fins 148 initially slide toward the receiving end of the holder 104 until the angled ends 150 of the longitudinal fins 148 move past the ends of the angled stops 154, at which point the longitudinal fins 148 temporarily disengage from the internal grooves 152 of the guide ring 130 and the carrier sleeve 132 begins to rotate. As the carrier sleeve 132 rotates, it begins to move in the opposite longitudinal direction (e.g., away from the receiving end of the holder 104), causing the angled ends 150 of the longitudinal fins 148 to slide into an adjacent set of internal grooves 152 in the guide ring 130. The longitudinal fins 148 then continue to slide within the internal grooves 152 in a direction away from the receiving end of the holder 104 until the first tube portion 144 of the carrier sleeve 132 abuts the guide ring 130. At this point, the ejection mechanism returns to the receiving position. Note that in some embodiments, a stop flange 158 can alternatively or additionally abut against the retaining ring 129 in the receiving position. In still other embodiments, other features can serve as stops for the receiving and / or ejection positions.

[0091] FIG. 8 shows a perspective view of the smoking article 100 with the removable cartridge 102 received in the holder 104 in a receiving position, and FIG. 9 shows a longitudinal cross-sectional view of the smoking article 100 of FIG. 8. In various embodiments, the carrier sleeve 132 and / or the cartridge 102 may include one or more retention features configured to retain the cartridge 102 within the carrier sleeve 132 after insertion. For example, in the illustrated embodiment, the cartridge 102 includes one or more protrusions 164 configured to interact with a portion of the receiving cavity 138 of the carrier sleeve 132 such that an interference fit or some other type of "retention" fit is created. In various embodiments, such a fit may allow the cartridge 102 to be retained within the carrier sleeve 132 after insertion, while simultaneously allowing the cartridge 102 to be removed after application of sufficient removal force, such as that applied by a user attempting to pull the cartridge 102 from the carrier sleeve 132. In some embodiments, the carrier sleeve 132, or portions thereof, may include complementary features, such as, for example, one or more recesses or indentations in which the protrusions 164 can be positioned. Note that other types of retention methods may be used in other embodiments, including, for example, one or more magnets disposed on the cartridge 102 and / or the carrier sleeve 132 (or one or more other components of the holder 104). Other embodiments may include a retention feature that extends from or is otherwise activated to cover the receiving end of the holder 104. For example, the retention feature may be used to retain the cartridge 102 within the holder 104 after it is inserted into its receiving end. In some embodiments, such a retention feature may comprise a mesh or screen structure constructed from a metallic material. For example, in some embodiments, the retention feature may be activated by a user to retain the cartridge 102 inserted into the holder 104 as the cartridge 102 is moved from the ejection position to the receiving position.

[0092] 10 shows a perspective view of the smoking article 100, showing the cartridge 102 in both the receiving position and the ejected position. In various embodiments, the ejected position can be useful, for example, for igniting the heat source 108 of the cartridge 102, and the receiving position can be useful, for example, for protecting the ignited heat source 108 from contact. Furthermore, in various embodiments, the ejected position can be useful for removing the cartridge 102 from and / or receiving the cartridge 102 into the carrier sleeve 132 of the holder 104. It should be noted that in the ejection position of the illustrated embodiment, the cartridge 102 is positioned at or slightly beyond the point where the entire heat source 108 extends beyond the receiving end of the holder 104; however, in the ejection position of other embodiments, the cartridge 102 may extend to a different position relative to the holder 104, such as a position where most of the heat source 108 extends beyond the receiving end of the holder 104 or a position where only a portion of the heat source 108 extends beyond the receiving end of the holder 104. It should be noted that in further embodiments, multiple ejection positions may be present. For example, some embodiments may include a first ejection position, as described above, and a second ejection position in which the cartridge can extend further beyond the receiving end of the holder 104. In this manner, the second ejection position may provide additional access to the cartridge 102 for removal and / or insertion within the holder 104. Additional embodiments may include a myriad of other ejection positions, which may comprise any position between the receiving position and a position in which the cartridge 102 is completely outside the holder 104.

[0093] Some embodiments may include a heat source extinguishing mechanism that can be activated by a user or automated. In one example, the smoking article ejection mechanism may include a third position that further retracts the cartridge 102 into the holder 104. In this manner, the heat source 108 may be moved away from the receiving end and opening 124 of the holder 104, such that the receiving end and opening 124 no longer provide sufficient airflow to keep the heat source 108 ignited, effectively extinguishing the heat source 108 therein. In other embodiments, the holder 104 may include an outer (or inner) sleeve configured to slide over the end opening 124 (and, in some embodiments, the receiving end) of the holder 104 to restrict or block airflow to the heat source 108. It should be noted that other extinguishing mechanisms are possible, such as other embodiments in which the heat source 108 is starved of oxygen to effectively extinguish it. In some embodiments, activation of the fire suppression mechanism may occur via mouthpiece 122 or another component and / or may be integrated with the exhaust mechanism, although in other embodiments other methods of activation are possible, including a separate fire suppression mechanism.

[0094] Some embodiments may include an ignition mechanism that can be activated by a user or automated. In one example, the ignition mechanism may include an integrated flint lighter that can be activated independently by a user or automatically when the ejection mechanism is activated. Other embodiments may include a fuel source, such as a fuel tank, that can be combined with an ignition device to generate a flame that ignites the heat source 108. In various embodiments, activation of the ignition mechanism may occur via the mouthpiece 122 or another component and / or may be integrated with the ejection mechanism.

[0095] In some embodiments, the smoking article 100 may further include an indicator configured to indicate the status of the cartridge 102. For example, in some embodiments, the indicator may provide a "fuel gauge" that estimates how much substrate material in the cartridge is available for aerosolization and / or how much substrate material has been aerosolized. Another example of such an indicator may include a thermochromatic visual indication of the substrate portion through its consumption cycle. Other examples may include a timer, clock, or progressive visual indicator that provides a visual representation of the status of the substrate material. For example, some embodiments may provide the visual representation in the form of a digital indicator, one or more color-changing components, one or more lights (e.g., green, yellow, and red), or other progressive indicator. In some embodiments, the indicator may indicate to the user that the substrate portion has heated sufficiently for the user to begin smoking.

[0096] Smoking articles according to the present disclosure may take on a variety of embodiments, as described in detail herein, although the use of the smoking article by a consumer will be similar in scope. The above description of the use of the smoking article is applicable to the various embodiments described, with minor modifications that 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 article of the present invention, but is provided to fulfill all necessary requirements of the disclosure herein.

[0097] Many modifications and other embodiments of the present disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the present disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A heat source and a substrate portion having opposed first and second ends, a heat source disposed proximate the first end of the substrate portion, the substrate portion comprising a substrate material having an aerosol precursor composition associated therewith; an outer housing configured to enclose the heat source and at least a portion of the substrate portion; 1. A removable cartridge for use with a reusable holder, comprising: an outer housing having an open end and a closed end, the closed end including one or more end openings configured to allow aerosol from the substrate material to pass therethrough; A removable cartridge, wherein the cartridge is configured to be removable and replaceable within the holder, and the heat source is positioned in a configuration abutting the first end of the substrate portion.

2. 10. The removable cartridge of claim 1, wherein the substrate material comprises at least one of tobacco-containing beads, shredded tobacco, strips of tobacco, reconstituted tobacco material, tobacco rods, and non-tobacco materials.

3. The removable cartridge of claim 1 , wherein the substrate material comprises a non-tobacco material.

4. The removable cartridge of claim 1 , wherein the heat source comprises an extruded monolithic carbonaceous material.

5. The removable cartridge of claim 1 , wherein the heat source defines one or more passages extending longitudinally from a first end of the heat source to an opposing second end of the heat source.

6. The removable cartridge of claim 1 , wherein the heat source defines one or more circumferential grooves extending longitudinally from a first end of the heat source to an opposing second end of the heat source.

7. The removable cartridge of claim 1 , wherein the substrate material comprises first and second substrate material segments, the second substrate material segment being disposed proximate the second end of the first substrate material.

8. 10. The removable cartridge of claim 1, wherein the second substrate material segment comprises at least one of tobacco-containing beads, shredded tobacco, strips of tobacco, reconstituted pieces of tobacco material, or a tobacco rod.

9. The removable cartridge of claim 1 , wherein the second substrate material segment comprises a non-tobacco material.

10. The removable cartridge of claim 1 , wherein the opening comprises a pair of elongated rounded slots.

11. The removable cartridge of claim 1 , wherein the outer housing is made of a rigid material.

12. The removable cartridge of claim 1 , wherein the outer housing has a tubular shape.

13. The removable cartridge of claim 1 , wherein the heat source is configured to generate heat when ignited.

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