Aerosol delivery device having a conductive insert

Abstract

To provide aerosol delivery devices.SOLUTION: An aerosol delivery device 100 comprises: an aerosol source member 200 that defines an outer surface 206 and an interior area 208 and includes a substrate material having an aerosol precursor composition coupled therewith; a control body 102 having a housing 104 that is configured to receive the aerosol source member 200; an electrical energy source 108 coupled with the housing 104; and a heating assembly 110 operatively connected to the electrical energy source 108. The heating assembly 110 includes a plurality of spikes 112 that may be configured to articulate between a retracted position, in which the spikes 112 are not in contact with the aerosol source member 200, and a heating position, in which the spikes 112 pierce through the outer surface of the substrate material into a portion of the interior area thereof.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to aerosol delivery articles and their use for producing tobacco components or other materials in inhalable form. More specifically, the present disclosure relates to aerosol delivery devices that utilize electrical heating to heat tobacco or non-tobacco materials, preferably without significant combustion, to provide the inhalable substance in the form of an 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 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., the entire contents of which are incorporated herein by reference.

[0003] The key to improving or replacing smoking articles has typically been to provide the sensation associated with smoking cigarettes, cigars, or pipes without delivering significant amounts of incomplete combustion and pyrolysis products.To this end, many smoking products, flavor generators, and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials, or to provide the sensation of smoking cigarettes, cigars, or pipes without significantly burning tobacco.See, for example, the various alternative smoking articles, aerosol delivery devices, and heat sources described in the background art of Robinson et al., U.S. Patent No. 7,726,320, 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 in their entirety. 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 in its entirety. 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 Count ... No. 5,388,594 to Higgins et al., U.S. Pat. No. 5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 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 to Kobayashi ,253, U.S. Patent No. 7,726,320 to Robinson et al., U.S. Patent No. 7,896,006 to Hamano, U.S. Patent No. 6,772,756 to Shayan, U.S. Patent Application Publication Nos. 2009 / 0095311 to Hon, U.S. Patent Application Publication Nos. 2006 / 0196518, 2009 / 0126745 and 2009 / 0188490 to Hon, U.S. Patent Application Nos. 2009 / 0126745 and 2009 / 0188490 to Thorens et al. 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 PCT Publication No. WO 2010 / 091593 to Hon.

[0004] Representative products that mimic many of the attributes of a traditional cigarette, cigar or pipe include ACCORD® by Philip Morris Incorporated, ALPHA™, JOYE 510™ and M4™ by InnoVapor LLC, CIRRUS™ and FLING™ by White Cloud Cigarettes, BLU™ by Fontem Ventures BV, COHITA™, COLIBRI™, ELITE CLASSIC™, MAGNUM™, PHANTOM™ and SENSE™ by EPUFFER® International Inc., DUOPRO™, STORM™ and VAPORKING® by Electronic Cigarettes, Inc., EGAR™ by Egar Australia, eGo-C™ and eGo-T™ by Joyetech, ELUSION™ by Elusion UK Ltd, and Eonsmoke. EONSMOKE® by FIN Branding Group, LLC, FIN™ by FIN Branding Group, LLC, SMOKE® by Green Smoke Inc., 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 and GLO™ by British American Tobacco. Still other electrically powered aerosol delivery devices, particularly those characterized as so-called e-cigarettes, are marketed under the trade names COOLER VISIONS™, DIRECT E-CIG™, DRAGONFLY™, EMIST™, EVERSMOKE™, GAMUCCI®, HYBRID FLAME™, KNIGHT STICKS™, ROYAL BLUES™, SMOKETIP®, and SOUTH BEACH SMOKE™. [Prior art documents] [Patent documents]

[0005] [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 Summary of the Invention [Problem to be solved by the invention]

[0006] Articles that produce the taste and sensation of smoking by electrically heating tobacco, tobacco-derived materials, or other plant-derived materials have suffered from inconsistent performance characteristics. For example, some articles have suffered from inconsistent release of flavors or other inhalable materials. Therefore, it may be desirable to provide a smoking article that can provide the smoking sensation of a cigarette, cigar, or pipe without burning substrate materials, without requiring a combustion heat source, and with improved performance characteristics. [Means for solving the problem]

[0007] In various embodiments, the present disclosure provides an aerosol delivery device, including, but not limited to, the following exemplary embodiments:

[0008] Exemplary embodiment 1: An aerosol delivery device comprising: an aerosol source member including a substrate material defining an outer surface and an interior region and having an aerosol precursor composition bound thereto; a control body having a housing configured to receive the aerosol source member; an electrical energy source coupled to the housing; and a heating assembly operably connected to the electrical energy source, wherein the heating assembly includes a plurality of spikes configured to articulate between a retracted position in which the plurality of spikes are not in contact with the aerosol source member and a heated position in which the plurality of spikes pierce the outer surface of the substrate material and enter a portion of the interior region thereof.

[0009] Exemplary Embodiment 2: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the outer surface of the substrate material includes a plurality of spaced apart conductive bands.

[0010] Exemplary Embodiment 3: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein each of the spaced apart conductive bands surrounds the entire outer surface of the substrate material.

[0011] Exemplary Embodiment 4: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein each of the spaced apart conductive bands can extend around a limited portion of the outer surface of the substrate material and define a first end and a second end.

[0012] Exemplary embodiment 5: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein in the heated position, each spike of the plurality of thermally conductive spikes contacts first and second ends of the spaced apart conductive bands.

[0013] Exemplary embodiment 6: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the plurality of spikes constitutes a heating element of the heating assembly.

[0014] Exemplary embodiment 7: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the plurality of spaced apart conductive bands comprises a heating element of the heating assembly.

[0015] Exemplary Embodiment 8: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the aerosol source member further comprises a second substrate material defining an outer surface and an interior region, the second substrate material substantially surrounding the first substrate material.

[0016] Exemplary embodiment 9: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the outer surface of the first substrate material includes a plurality of spaced apart conductive bands.

[0017] Exemplary embodiment 10: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein each of the spaced apart conductive bands surrounds the entire outer surface of the substrate material.

[0018] Exemplary Embodiment 11: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein each of the spaced apart conductive bands extends around a portion of the outer surface of the substrate material and defines a first end and a second end.

[0019] Exemplary embodiment 12: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein in the heated position, each spike of the plurality of spikes contacts first and second ends of the spaced apart conductive bands.

[0020] Exemplary embodiment 13: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the plurality of spikes comprises a heating element of the heating assembly.

[0021] Exemplary embodiment 14: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the plurality of spaced apart conductive bands comprises a heating element of the heating assembly.

[0022] Exemplary embodiment 15: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the substrate material comprises at least one of a tobacco material and a tobacco-derived material.

[0023] Exemplary Embodiment 16: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the substrate material comprises a non-tobacco material.

[0024] Exemplary Embodiment 17: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the first substrate material contains a first composition and the second substrate material contains a second composition, and the first composition is different from the second composition.

[0025] Exemplary Embodiment 18: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the substrate material contains at least one of shredded tobacco material, beads of tobacco material, extruded structures of tobacco material, crimped sheets of tobacco material, and combinations thereof.

[0026] Exemplary embodiment 19: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the first substrate material contains at least one of shredded tobacco material, beads of tobacco material, an extruded structure of tobacco material, a crimped sheet of tobacco material, and combinations thereof.

[0027] Exemplary embodiment 20: The aerosol delivery device of any preceding exemplary embodiment, or any combination of any preceding exemplary embodiment, wherein the second substrate material contains at least one of shredded tobacco material, beads of tobacco material, an extruded structure of tobacco material, a crimped sheet of tobacco material, and combinations thereof.

[0028] 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.

[0029] Aspects of 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]

[0030] [Figure 1] 1 shows a schematic front view of an aerosol delivery device including a control body, an aerosol source member, and a heating assembly according to an exemplary embodiment of the present disclosure. [Figure 2] 1 shows a schematic front view of a portion of the heated end of an aerosol source member and a portion of a heating assembly according to an exemplary embodiment of the present disclosure. [Figure 3] 1 shows a perspective schematic view of a portion of the heated end of an aerosol source member and a portion of a heating assembly according to an exemplary embodiment of the present disclosure. [Figure 4] 1 shows a perspective schematic view of a portion of a heated end of an aerosol source member according to an exemplary embodiment of the present disclosure. [Figure 5] 1 shows a perspective schematic view of a portion of the heated end of an aerosol source member and a portion of a heating assembly according to an exemplary embodiment of the present disclosure. [Figure 6] 1 shows a schematic top view of the heated end of the aerosol source member and a portion of the heating assembly according to an exemplary embodiment of the present disclosure. [Figure 7] 1 shows a perspective schematic view of a portion of the heated end of an aerosol source member and a portion of a heating assembly according to an exemplary embodiment of the present disclosure. [Figure 8] 1 shows a schematic top view of the heated end of the aerosol source member and a portion of the heating assembly according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0031] 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, the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the appended claims, the singular forms "a," "an," "the," and the like, include plural referents unless the context clearly dictates otherwise. Also, while the specification may refer to quantitative measures, values, geometric relationships, and the like, unless otherwise stated, any one or more of these may be absolute or approximate to account for possible permissible variations, such as those due to technical tolerances.

[0032] As described below, exemplary embodiments of the present disclosure relate to aerosol delivery devices for use with aerosol source members. Aerosol delivery devices according to the present disclosure use electrical energy to heat a material (preferably without significantly burning the material) to form an inhalable substance. Components of such systems have the form of items small enough to be considered handheld devices. That is, preferred aerosol delivery device components do not produce smoke, in the sense that the aerosol is primarily generated from by-products of tobacco combustion or pyrolysis; rather, these preferred systems produce vapor resulting from the volatilization or vaporization of certain components incorporated therein. In some exemplary embodiments, aerosol delivery device components may be characterized as electronic cigarettes, which most preferably incorporate tobacco and / or tobacco-derived components and thus deliver the tobacco-derived components in aerosol form.

[0033] The aerosol-generating components of certain preferred aerosol delivery devices may provide many of the sensations (e.g., inhalation and exhalation patterns, types of tastes or flavors, organoleptic effects, physical sensations, modes of use, visual cues such as those provided by visible aerosols, 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 components, 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.

[0034] Although the systems are generally described herein with respect to embodiments relating to aerosol delivery devices, 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 may be used in combination 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 relating to aerosol delivery devices, and may be embodied in and used in a variety of other products and methods.

[0035] The aerosol delivery device of the present disclosure can also be characterized as a vapor product or drug delivery article. Accordingly, such an article or device may be adapted to provide one or more substances (e.g., flavors and / or active pharmaceutical ingredients) in an inhalable form or state. For example, the inhalable substance may be substantially in vapor form (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance may be in aerosol form (i.e., 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. The physical form of the inhalable substance is not necessarily limited by the nature of the device of the present disclosure, but may depend on the nature of the medium and the inhalable substance itself, with respect to whether the inhalable substance exists in a vapor or aerosol state. In some embodiments, terms may be interchangeable. Therefore, for simplicity, terms used to describe aspects of the present disclosure are understood to be interchangeable unless otherwise specified.

[0036] The aerosol delivery device of the present disclosure generally includes multiple components disposed within an outer body or shell, which may be referred to as a housing. The overall design of the outer body or shell can vary, and the type or configuration of the outer body can vary, which can define the overall size and shape of the aerosol delivery device. Typically, an elongated body resembling the shape of a cigarette or cigar, or a fob-shaped body, can be formed from a single, integral housing, or the housing can be formed from two or more separable bodies. For example, the aerosol delivery device can include an elongated shell or body that is substantially tubular in shape and can resemble the shape of a traditional cigarette or cigar. In another example, the aerosol delivery device can have a box or fob shape. In one example, all components of the aerosol delivery device are contained within a single housing. Alternatively, the aerosol delivery device can include two or more joined and separable housings. For example, the aerosol delivery device may have a control body comprising a housing containing one or more reusable components (e.g., a storage battery, such as a rechargeable battery and / or a rechargeable supercapacitor, and various electronics for controlling the operation of the item), and a disposable portion (e.g., a disposable flavor-containing aerosol source member) removably coupleable thereto. More specific forms, configurations, and arrangements of components within a single-housing type unit or a multi-part separable-housing type unit will become apparent in light of the further disclosure provided herein. Additionally, various aerosol delivery device designs and component arrangements may be understood in light of commercially available electronic aerosol delivery devices.

[0037] As described in further detail below, the aerosol delivery device of the present disclosure may comprise some combination of a power source (i.e., a source of electrical energy), at least one control component (e.g., a means for activating, controlling, regulating, and terminating electrical power for heat generation, such as by controlling the flow of electrical current from the electrical energy source to other components of the device (e.g., a microprocessor, either individually or as part of a microcontroller)), a heater or heat-generating member (e.g., an electrical resistance heating element or other component and / or an induction coil or other associated component and / or one or more radiant heating elements), and an aerosol source member including a substrate material capable of generating an aerosol upon application of sufficient heat. In various embodiments, the aerosol source member may include a mouth end or tip configured to allow inhalation of the aerosol delivery device for aerosol inhalation (e.g., a defined air flow path through the device so that generated aerosol can be drawn therefrom upon inhalation).

[0038] The arrangement of components within the aerosol delivery device of the present disclosure may vary across various embodiments. In some embodiments, the substrate material of the aerosol source member may be positioned in close proximity to the heating member to maximize aerosol delivery to the user, although other configurations are not excluded. Generally, the heating member may be positioned sufficiently close to the substrate material so that heat from the heating member can volatilize the substrate material (and, in some embodiments, one or more flavorings, medications, etc., that may also be provided for delivery to the user) and form an aerosol for delivery to the user. When the heating member heats the substrate material, 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, inhalable substances are released in the form of vapors or aerosols or mixtures thereof, and such terms are used interchangeably herein unless otherwise specified.

[0039] As noted above, various embodiments of the aerosol delivery device may incorporate a battery and / or other power source to provide a sufficient flow of electrical current to provide various functions for the aerosol delivery device, such as powering the heating element, powering the control system, powering the indicators, etc. As described in further detail below, the electrical energy source may take various embodiments. Preferably, the electrical energy source may be capable of providing sufficient power to rapidly activate the heating element to form the aerosol and power the aerosol delivery device throughout use for a desired duration. The electrical energy source is preferably sized to fit conveniently within the aerosol delivery device to allow for easy handling of the aerosol delivery device.

[0040] In further embodiments, the electrical energy source may also include a capacitor. Capacitors can discharge faster than batteries and can be charged between puffs, allowing the capacitor to discharge at a slower rate than if a battery were used to directly power the heating element. For example, a supercapacitor, such as an electric double-layer capacitor (EDLC), may be used separately from or in combination with a battery. If used alone, the supercapacitor may be charged before each use of the device. Therefore, the device may also include a charger component that can be attached to the smoking device between uses to replenish the supercapacitor.

[0041] Additional components are available for the aerosol delivery device of the present disclosure. For example, the aerosol delivery device may include a flow sensor (e.g., a puff-activated switch) that is sensitive to either pressure or airflow changes when a consumer inhales on the device. Other possible current activation / deactivation mechanisms may include a temperature-activated on / off switch or a lip-pressure-activated switch. An exemplary mechanism that can provide such puff activation capability includes the Model 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc. of Freeport, Illinois. Representative flow sensors, current regulation components, and other current control components, including various microcontrollers, sensors, and switches, for aerosol delivery devices are described in U.S. Patent No. 4,735,217 to Gerth et al., U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,875, all of which are incorporated herein by reference in their entirety, U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., and U.S. Patent No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entirety. Reference is also made to the control scheme described in U.S. Patent No. 9,423,152 to Ampolini et al., all of which are incorporated herein by reference in their entirety.

[0042] In another example, a personal vaporizer unit may include a first conductive surface configured to contact a first body part of a user holding the personal vaporizer unit, and a second conductive surface configured to contact a second body part of the user, the second conductive surface being conductively isolated from the first conductive surface. Thus, when the personal vaporizer unit detects a change in conductivity between the first and second conductive surfaces, the vaporizer is activated to vaporize the substance, resulting in vapor that can be inhaled by the user holding the unit. The first and second body parts may be the lips or a portion of the hand. The two conductive surfaces may also be used to charge a battery housed in the personal vaporizer unit. The two conductive surfaces may also form or be part of a connector that can be used to output data stored in the memory. See U.S. Pat. No. 9,861,773 to Terry et al., incorporated herein by reference in its entirety.

[0043] Additionally, U.S. Patent No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Patent No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouth end of a device that detects a user's lip movement associated with drawing and subsequently causes heating of the heating device; U.S. Patent No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow to a heating load array in response to a drop in pressure through a mouthpiece; and U.S. Patent No. 5,372,148 to Ha U.S. Pat. No. 5,967,148 to Rris et al. discloses a canister in a smoking system that includes an identifier that detects non-uniformity in the infrared transmittance of an inserted component and a controller that executes a detection routine when the component is inserted into the canister; U.S. Pat. No. 6,040,560 to Fleischhauer et al. describes predefined viable power cycles with multiple differential phases; and U.S. Pat. No. 5,934,289 to Watkins et al. describes photonic-optical components. No. 5,954,979 to Counts et al. discloses a means for varying the resistance to draw through a smoking device; U.S. Pat. No. 6,803,545 to Blake et al. discloses particular battery configurations for use in smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses a computer interface means for a smoking device to facilitate charging and enable computer control of the device; U.S. Pat. No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device; and PCT Publication No. WO 2010 / 003480 to Flick discloses a fluid flow sensing system to indicate a puff using an aerosol generating system, all of the foregoing disclosures are incorporated herein by reference in their entireties.

[0044] Additional examples of components related to electronic aerosol delivery articles and disclosed materials or components usable in the present devices include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 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. 7,513,253 to Kobayashi, U.S. Pat. No. 7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. No. 8,832,410 to Hon, U.S. Pat. No. 8,832,410 to Hon, U.S. Pat. No. 8,832,410 to Hon, U.S. Pat. No. 8,832,410 to Hon, U.S. Pat. No. 8,513,253 ... Nos. 156,944 and 8,375,957 to Thorens et al., 8,794,231 to Thorens et al., 8,851,083 to Oglesby et al., 8,915,254 and 8,925,555 to Monsees et al., 9,220,302 to DePiano et al., and U.S. Patent Application Publication No. 2006 / 01965 to Hon.

[0009] Examples of such a method include U.S. Patent Application Publication No. 2009 / 0188490 to Oglesby et al., U.S. Patent Application Publication No. 2010 / 0024834 to Wang, U.S. Patent Application Publication No. 2010 / 0307518 to Hon, PCT International Publication No. 2010 / 091593 to Hon, and PCT International Publication No. 2013 / 089551 to Foo, each of which is incorporated herein by reference in its entirety. Furthermore, U.S. Patent Application Publication No. 2017 / 0099877 to Worm et al., filed October 13, 2015, discloses an aerosol delivery device and a capsule that can be included in a fob-shaped configuration for the aerosol delivery device, and is incorporated herein by reference in its entirety. In various embodiments, various materials disclosed by the aforementioned documents may be incorporated into the device, and all of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0045] More specific forms, configurations, and arrangements of the various substrate materials, aerosol source members, and components within the aerosol delivery devices of the present disclosure will become apparent in light of the further disclosure provided below. Additionally, the selection of various aerosol delivery device components may be understood in light of commercially available electronic aerosol delivery devices. Furthermore, the arrangement of components within the aerosol delivery device may be understood in light of commercially available electronic aerosol delivery devices.

[0046] A front schematic view of an exemplary embodiment of an aerosol delivery device 100 according to the present disclosure is shown in FIG. 1. Generally, the aerosol delivery device 100 of the illustrated embodiment includes a control body 102 including a housing 104 configured to receive an aerosol source member 200. In the illustrated embodiment, the control body 102 may include a control component 106 (e.g., a microprocessor, either separately or as part of a microcontroller, a printed circuit board (PCB) including the microprocessor and / or microcontroller, etc.) and an electrical energy source 108 (e.g., a battery, which may be rechargeable, and / or a rechargeable supercapacitor). In various embodiments, one or both of the control component 106 and the electrical energy source 108 may be coupled to the housing 104. For purposes of this application, the phrase "coupled" when used with respect to one component as compared to another component may encompass embodiments in which one component is disposed within another component and / or embodiments in which one component is separate but otherwise operably connected to another component. For example, in the illustrated embodiment, both the control component 106 and the electrical energy source 108 are disposed within the housing. However, in other embodiments, one or both of the control component 106 and the electrical energy source 108 may be separate components. Additional information regarding the control component 106 and the electrical energy source 108 is provided below. In some embodiments, the housing 104 may also include a push button configured to activate a specific operation of the device 100, such as, for example, turning the device on and initiating heating of the heating element. In various embodiments, the aerosol source member 200 may include a heated end 202 configured to be inserted into the control body 102 and a mouth end 204 through which a user draws to generate the aerosol.It should be noted that while the aerosol delivery device of FIG. 1 is shown as having a substantially rectangular or fob-shaped control body 102 for ease of illustration, in other embodiments, the control body 102 may have any other shape, including an elongated shell or body that is substantially tubular in shape and thus may resemble the shape of a traditional cigarette or cigar, and therefore the components described below may be sized and configured to fit inside the elongated body.

[0047] In certain embodiments, one or both of the control body 102 and the aerosol source member 200 may be referred to as disposable or reusable. For example, the control body 102 may have a replaceable or rechargeable battery, a solid-state battery, a thin-film solid-state battery, a rechargeable supercapacitor, or the like, and thus may be combined with any type of charging technology, including connection to a wall charger, a connection to an automobile charger (i.e., cigarette lighter socket), a connection to a computer via a universal serial bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), or the like, a connection to a photovoltaic cell (sometimes called a solar cell) or solar panel, a wireless charger such as a charger using inductive wireless charging (e.g., including wireless charging compliant with the Qi wireless charging standard by the Wireless Power Consortium (WPC)), or a radio frequency (RF)-based charger. An example of an inductive wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is incorporated herein by reference in its entirety. Furthermore, in some embodiments, the aerosol source member 200 may comprise a disposable device. Disposable components for use with control bodies are disclosed in US Pat. No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0048] As described above, the control body 102 may further include a control component 106. For example, the control component 106 may include a control circuit (which may be connected to additional components, as further described herein) connectable to an electrical energy source 108 by conductive wires. In various embodiments, the control component 106 may control when and how the heating element receives electrical energy to heat the inhalable substance medium for release of the inhalable substance for inhalation by the consumer. Such control may relate to the actuation of a pressure-sensitive switch, or the like, described in further detail below. Note that the terms “connected” or “coupled” should not be interpreted as requiring a direct connection without intervening components. Rather, these terms may encompass a direct connection and / or a connection via one or more intervening components. Thus, in various embodiments, these terms will be understood to mean operably connected or operably coupled.

[0049] In various embodiments, the control component 106 may also be configured to precisely control the amount of heat provided to the substrate material. While the heat required to volatilize a sufficient volume of aerosol-forming substance to provide the desired dose of inhalable substance per puff may vary for each particular substance used, it may be particularly useful to heat the heating element to a temperature of at least 120°C, at least 130°C, or at least 140°C. In some embodiments, the heating temperature may be at least 150°C, at least 200°C, at least 300°C, or at least 350°C to volatilize an adequate amount of aerosol-forming substance and thus provide the desired dose of inhalable substance. However, it may be particularly desirable to avoid heating to temperatures substantially above about 550°C to avoid degradation and / or excessive premature volatilization of the aerosol-forming substance. In particular, heating should be at a temperature low enough and for a time short enough to avoid significant combustion (preferably any combustion) of the inhalable substance medium. The present disclosure may provide components of the present article in combinations and modes of use that produce the desired amount of inhalable substance at relatively low temperatures. Thus, yield may refer to one or both of the generation of aerosol within the article and its delivery to the consumer. In certain embodiments, the heating temperature may be about 120°C to about 300°C, about 130°C to about 290°C, about 140°C to about 280°C, about 150°C to about 250°C, or about 160°C to about 200°C. As described in more detail below, the duration of heating can be controlled by several factors. As described further herein, the heating temperature and duration may depend on the desired volume of aerosol and ambient air desired to be drawn through the aerosol source element. However, because the article can be configured such that the heating element is energized only until the desired temperature is reached, the duration may vary depending on the heating rate of the heating element. Alternatively, the duration of heating may be tied to the duration of a puff by the consumer using the article. Generally, the temperature and duration of heating are controlled by one or more components housed in the control body, as described above.

[0050] The amount of inhalable material emitted by the aerosol source member can vary based on the properties of the inhalable material. Preferably, the aerosol source member is comprised of a sufficient amount of inhalable material, along with a sufficient amount of any aerosol-forming agent, to function at a sufficient temperature for a sufficient time to emit the desired amount over the course of use. The amount may be provided in a single inhalation from the aerosol source member, or may be divided up to be provided through several puffs from the article over a relatively short period of time (e.g., less than 30 minutes, less than 20 minutes, less than 15 minutes, less than 10 minutes, or less than 5 minutes). For example, the device may provide an amount of nicotine of about 0.05 mg to about 1.0 mg, about 0.08 mg to about 0.5 mg, about 0.1 mg to about 0.3 mg, or about 0.15 mg to about 0.25 mg per puff with the aerosol source member. In other embodiments, the desired amount may be characterized in terms of the amount of wet total particulate matter delivered based on the duration and volume of the puff. For example, the aerosol source member may deliver at least 1.0 mg of wet total particulate matter per puff when smoked under standard FTC smoking conditions of a 2-second, 35 ml puff for a specified number of puffs (as described elsewhere herein). Such testing may be performed using any standard smoking machine. In other embodiments, the amount of total particulate matter (TPM) produced under the same conditions for each puff may be at least 1.5 mg, at least 1.7 mg, at least 2.0 mg, at least 2.5 mg, at least 3.0 mg, between about 1.0 mg and about 5.0 mg, between about 1.5 mg and about 4.0 mg, between about 2.0 mg and about 4.0 mg, or between about 2.0 mg and about 3.0 mg.

[0051] As mentioned above, the aerosol delivery device 100 of some embodiments may include a push button that can be coupled to a control component for manual control of the heating assembly 110. For example, in some embodiments, a consumer may use the push button to energize the heating assembly 110. Similar functionality associated with the push button may be achieved by other mechanical or non-mechanical means (e.g., magnetic or electromagnetic). Thus, activation of the heating assembly 110 can be controlled by a single push button. Alternatively, multiple push buttons may be provided to separately control various operations. If present, the one or more push buttons may be located substantially flush with the casing of the control body 102.

[0052] Instead of (or in addition to) any push button, the aerosol delivery device 100 of the present disclosure may include a component that energizes the heating assembly 110 in response to a consumer drawing on an article (i.e., puff-activated heating). For example, the device may include a switch or flow sensor (not shown) within the control body 102 that is sensitive to either pressure or airflow changes when a consumer draws on an article (i.e., puff-activated switch). Other suitable current activation / deactivation mechanisms may include a temperature-activated on / off switch or a lip-pressure-activated switch. An exemplary mechanism capable of providing such puff-activation capability includes the Model 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc. of Freeport, Illinois. With such a sensor, pressure changes when a consumer draws on the device can rapidly activate the heating element. Additionally, a flow-sensing device, such as one that uses the principles of hot-wire anemometry, may be used to energize the heating assembly sufficiently quickly after sensing a change in airflow. An additional purge-activated switch that can be used is a pressure differential switch, such as Model No. MPL-502-V, Range A, manufactured by Micro Pneumatic Logic, Inc. of Fort Lauderdale, Florida. Another suitable purge-activated mechanism is a pressure-sensitive transducer (e.g., with an amplifier or gain stage) coupled to a comparator for detecting a predetermined threshold pressure. Yet another suitable purge-activated mechanism is a vane deflected by airflow, the movement of which is detected by a motion-sensing means. Yet another suitable activation mechanism is a piezoelectric switch. Also useful is a suitably connected Honeywell MicroSwitch Microbridge Airflow Sensor, Part No. AWM 2100V, manufactured by the MicroSwitch Division of Honeywell, Inc. of Freeport, Illinois. Additional examples of demand-operated electrical switches that can be used in heating circuits according to the present disclosure are described in U.S. Pat. No. 4,735,217 to Gerth et al., which is incorporated herein by reference in its entirety.Other suitable differential switches, analog pressure sensors, flow sensors, and the like will be apparent to those skilled in the art with knowledge of this disclosure. In some embodiments, control body 102 may include a pressure sensing tube or other passageway that provides a fluid connection between the puff-activated switch and aerosol source member 200 so that pressure changes during inhalation can be easily identified by the switch. Other exemplary puff-activated devices that may be useful in accordance with the present disclosure are disclosed in U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,874 to Brooks et al., U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., and U.S. Pat. No. 7,040,314 to Nguyen et al., all of which are incorporated herein by reference in their entireties.

[0053] When a consumer draws on the mouth end of the device 100, the current actuation means ensures that the flow of current through the heating assembly is unrestricted or uninterrupted, allowing for rapid heat generation. For rapid heating, it may be useful to include current regulation components to (i) regulate the flow of current through the heating element to control heating of the resistive element and the resulting temperature, and (ii) prevent overheating and degradation of the substrate material 210. In some embodiments, the current regulation circuitry may be time-based. Specifically, such a circuitry may include means for ensuring that the flow of current through the heating element is uninterrupted for an initial period during inhalation, followed by timer means for regulating the current flow until inhalation is complete. For example, subsequent regulation may include rapid on / off switching of the current flow (e.g., on the order of about every 1-50 milliseconds) to maintain the heating element within a desired temperature range. Furthermore, regulation may comprise simply ensuring that the current flow is uninterrupted until the desired temperature is achieved, and then turning the current flow off completely. The heating element may be reactivated by the consumer initiating another puff on the item (or by manually activating a push button, depending on the particular switch embodiment used to activate the heater). Alternatively, subsequent adjustments may involve modulating the flow of current through the heating element to maintain the heating element within a desired temperature range. In some embodiments, the heating element may be energized for a duration of about 0.2 seconds to about 5.0 seconds, about 0.3 seconds to about 4.0 seconds, about 0.4 seconds to about 3.0 seconds, about 0.5 seconds to about 2.0 seconds, or about 0.6 seconds to about 1.5 seconds to emit a desired dose of inhalable substance. One exemplary time-based current regulation circuit may include a transistor, a timer, a comparator, and a capacitor. Suitable transistors, timers, comparators, and capacitors are commercially available and will be apparent to those skilled in the art. Exemplary timers are those available from NEC Electronics as C-1555C and from General Electric Intersil, Inc. as ICM7555, as well as other so-called "555 timers" in various sizes and configurations.An exemplary comparator is available from National Semiconductor as LM311. Additional description of such time-based current regulation circuits is provided in U.S. Patent No. 4,947,874 to Brooks et al., which is incorporated herein by reference in its entirety.

[0054] In light of the above, it can be appreciated that various mechanisms can be used to facilitate activation / deactivation of current to the heating element. For example, the device may include a timer for regulating the flow of current through the article (such as during inhalation by the consumer). The device may further include a timer-responsive switch for enabling and disabling the flow of current to the heating element. Regulating the flow of current may also include the use of a capacitor and components for charging and discharging the capacitor at a prescribed rate (e.g., a rate approximating the rate at which the heating element heats and cools). The flow of current may be regulated so that the flow of current through the heating element is uninterrupted, particularly for an initial period during inhalation, but the flow of current may be turned off or cycled alternately on and off after the initial period until inhalation is completed. Such cycles may be controlled by a timer capable of generating preset switching cycles, as described above. In certain embodiments, the timer may generate a periodic digital waveform. The flow during the initial period may be further regulated by using a comparator that compares a first voltage at a first input with a threshold voltage at a threshold input and generates an output signal when the first voltage equals the threshold voltage, thereby enabling the timer. Such an embodiment may further include a component for generating a threshold voltage at the threshold input, and a component for generating a threshold voltage at the first input upon passage of an initial period of time.

[0055] As noted above, the electrical energy source 108 used to power the various electrical components of the device 100 may take on a variety of embodiments. Preferably, the electrical energy source provides sufficient energy to rapidly heat the heating assembly in the manner described above and can power the device through use with multiple aerosol source members 200 while still fitting conveniently into the device 100. Examples of useful electrical energy sources include, preferably, rechargeable lithium-ion batteries (e.g., rechargeable lithium manganese dioxide batteries). In particular, lithium polymer batteries can be used because such batteries can improve safety. Other types of batteries, such as nickel-cadmium batteries, may also be used. Furthermore, preferred electrical energy sources are lightweight enough so as not to detract from the desired smoking experience. Some examples of possible electrical energy sources are described in U.S. Pat. No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191 to Sur et al., filed October 21, 2015, the entire disclosures of each of which are incorporated herein by reference.

[0056] One example of an electrical energy source is the TKI-1550 rechargeable lithium-ion battery manufactured by Tadiran Batteries GmbH in Germany. In another embodiment, a useful electrical energy source may be an N50-AAA CADNICA nickel-cadmium battery manufactured by Sanyo Electric Company, Ltd. in Japan. In other embodiments, multiple such batteries, each providing 1.2 volts, may be connected in series. Other electrical energy sources, such as rechargeable lithium manganese dioxide batteries, may also be used. While any of these batteries or combinations thereof can be used as the electrical energy source, rechargeable batteries are preferred due to cost and disposal considerations associated with disposable batteries. In embodiments in which a rechargeable battery is used, the aerosol delivery device 100 may further include charging contacts that interact with corresponding contacts in a standard 120-volt AC wall outlet or a conventional charging unit (not shown) that obtains power from another source, such as an automobile's electrical system or a separate portable power source. In further embodiments, the electrical energy source may also include a capacitor. Capacitors can discharge faster than batteries and can be charged between puffs, allowing the capacitor to discharge at a slower rate than if a battery were used to directly power the heating element. For example, a supercapacitor, i.e., an electric double layer capacitor (EDLC), may be used separately from or in combination with a battery. If used alone, the supercapacitor may be charged before each use of the device 100. Thus, the present disclosure may also include a charger component attachable to the device between uses to replenish the supercapacitor. In certain embodiments of the present disclosure, a thin-film battery may be used.

[0057] As noted above, in various embodiments, the aerosol delivery device 100 may include one or more indicators (not shown). In various embodiments, the one or more indicators may be located anywhere on the control body 102. In some embodiments, the indicators may be lights (e.g., light-emitting diodes) that can provide indications of multiple aspects of the device's use. For example, a series of lights may correspond to the number of puffs taken on a given aerosol source member. Specifically, the lights may be illuminated sequentially with each puff, such that when all lights are illuminated, the consumer is notified that the aerosol source member has been consumed. Alternatively, all lights may be illuminated when the aerosol source member is inserted into the housing, and the lights may be turned off with each puff, such that when all lights are turned off, the consumer is notified that the aerosol source member has been consumed. In still other embodiments, there may be only a single indicator, the illumination of which may indicate that current is flowing to the heating member and that the device is actively heating. This may prevent consumers from unintentionally leaving the device in active heating mode. In alternative embodiments, one or more of the indicators may be components of the aerosol source member. While the indicators are described above in connection with on / off visual indicators, other operational indicators are also encompassed. For example, visual indicators may also include changes in light color or intensity to indicate the progression of the smoking experience. Tactile and audible indicators are also encompassed by the present disclosure. Furthermore, combinations of such indicators may be used in a single device.

[0058] In various embodiments, the housing 104 may be formed from any material suitable for forming and maintaining a suitable structure, such as a tubular or rectangular shape, and for retaining the aerosol source member therein. In some embodiments, the housing may be formed from a single wall or multiple walls and from one or more materials (natural or synthetic) that are heat-resistant so as to maintain its structural integrity (e.g., not deteriorate) at least at temperatures that are the heating temperatures provided by the electric heating element, as further described herein. In some embodiments, heat-resistant polymers may be used. In other embodiments, ceramic materials may be used. In further embodiments, insulating materials may be used to prevent unnecessary heat transfer from the aerosol source element. When formed from a single layer, the housing may preferably have a thickness of about 0.2 mm to about 5.0 mm, about 0.5 mm to about 4.0 mm, about 0.5 mm to about 3.0 mm, or about 1.0 mm to about 3.0 mm. Additional exemplary types of components and materials that can be used to provide the above functionality or that can be used as substitutes for the above materials and components can be of the type described in U.S. Patent Application Publication No. 2010 / 00186757 to Crooks et al., U.S. Patent Application Publication No. 2010 / 00186757 to Crooks et al., and U.S. Patent Application Publication No. 2011 / 0041861 to Sebastian et al., the entire disclosures of which are incorporated herein by reference.

[0059] 1 and 2 , the aerosol source member 200 defines an exterior surface 206 and an interior region 208. In the illustrated embodiment, the substrate material 210 is disposed in the interior region 208 of the heated end 202 of the aerosol source member 200. However, in some embodiments, the substrate material may be disposed in both the heated end 202 and the mouth end 204 of the aerosol source member 200. In the illustrated embodiment, the substrate material 210 has a single segment; however, in other embodiments, the substrate material 210 may include additional segments that may have different compositions. For example, the heated end 202 of some embodiments of the aerosol source member 200 may further comprise a second substrate material segment (not shown). In various embodiments, one or more of the substrate materials may contain 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, with the understanding that the following description should be applicable to any substrate material or substrate material segment that can be used in the aerosol delivery devices described herein.

[0060] In various embodiments, the aerosol source member 200, or a portion thereof, may be encased in an outer overwrap material. In various embodiments, the mouth end 204 of the aerosol source member 200 may include a filter, which may be made, for example, from a cellulose acetate material or a polypropylene material. 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., incorporated herein by reference in its entirety. In various embodiments, the filter may enhance the structural integrity of the mouth end of the aerosol source member and / or provide optional filtration capabilities and / or resistance to suction. The outer overwrap material may comprise a material that resists heat transfer, which may include paper or other fibrous materials, such as cellulose materials. The outer overwrap material may also contain at least one filler material embedded or dispersed within the fibrous material. In various embodiments, the filler material may have the form of water-insoluble particles. Additionally, the filler material may incorporate inorganic components. In various embodiments, the outer overwrap may be formed from multiple layers, such as an underlying bulk layer, and an overlying layer, such as a paper wrapper typical of cigarettes. Such materials can include, for example, lightweight "rag fibers" such as flax, hemp, sisal, rice straw, and / or esparto. The outer overwrap may also contain materials typically used in filter elements of conventional cigarettes, such as cellulose acetate. Additionally, excess length of the outer overwrap at the mouth end 204 of the aerosol source member can function to simply separate the substrate material from the consumer's mouth, to provide space for placement of a filter material, to affect draw on the article, or to affect the flow characteristics of vapor or aerosol exiting the device during draw, as described below. Additional description regarding the configuration of outer overwrap materials usable with the present disclosure can be found in U.S. Pat. No. 9,078,473 to Worm et al., incorporated herein by reference in its entirety.

[0061] Generally, the shape and dimensions of the various embodiments of the aerosol source member described herein depend on the size of the housing, the physics of heat and mass transfer related to the shape design, and / or the expected puff count of the aerosol source member. While a variety of different shapes (e.g., cylindrical, cubic, spherical, etc.) and dimensions are possible, in some embodiments, an aerosol source member having a cylindrical shape may have an overall diameter of about 5.4 mm and a length of about 83 mm. In other embodiments, an aerosol source member may have an overall diameter of about 7-8 mm (e.g., about 7.8 mm) or more. In other embodiments, an aerosol source member having a cubic shape may have dimensions of about 70 mm x 20 mm x 6 mm. In any of these examples, the dimensions may vary widely, for example, by ±50% in any dimension.

[0062] In various embodiments, heating of the substrate material 210 results in aerosolization of the aerosol precursor composition bound to the substrate material 210. In various embodiments, the mouth end 204 of the aerosol source member 200 is configured to receive the generated aerosol therethrough in response to suction applied to the mouth end 204 by a user. As mentioned above, the mouth end 204 of the aerosol source member 200 of some embodiments may include a filter configured to receive the aerosol therethrough in response to suction applied to the mouth end 204 of the aerosol source member. Preferably, the elements of the substrate material 210 do not significantly pyrolyze (e.g., char, scorch, or burn), and the aerosolized components are entrained in air, which is drawn through the aerosol delivery device 100, including the filter (if present), and into the user's mouth.

[0063] In one embodiment, the substrate material may contain a blend of flavorful, aromatic tobaccos in cut filler form. In another embodiment, the substrate material may contain 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 include 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 include 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 a laminated sheet of reconstituted tobacco material. In some embodiments, the substrate material may comprise overlapping layers (e.g., a gathered web) that may or may not include a thermally conductive component. Examples of substrate materials comprising a series of overlapping layers (e.g., a gathered web) of an initial substrate sheet formed by a fibrous filler material, an aerosol-forming material, and multiple thermally conductive components are 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.

[0064] In some embodiments, the substrate material may contain a plurality of microcapsules, beads, granules, etc., having tobacco-related material. For example, a typical microcapsule may be approximately spherical in shape and have an outer cover or shell containing a liquid center region, such as a tobacco-derived extract. 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 contain a binder material configured to maintain the structural shape and / or integrity of the plurality of microcapsules formed in a hollow cylindrical shape.

[0065] 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, the disclosures of which are incorporated herein by reference in their entireties. No. 6,701,936 to Li 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 International Publication No. 02 / 37990 to Bereman, and Fund. Appl. Toxicol., 39, pp. 11-17 (1997).

[0066] In still other embodiments of the present disclosure, the substrate material may contain an extruded structure that contains 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 contain fine cellulose or nanocellulose derived from tobacco or other biomass.

[0067] 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.

[0068] 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 drugs such as nicotine) may comprise up to about 10%, up to about 8%, or up to about 5% by weight of the aerosol delivery components.

[0069] 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 contain 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.

[0070] In some embodiments, the amount of substrate material used in the aerosol delivery device may be such that the article exhibits acceptable sensory and organoleptic properties, as well as desirable performance characteristics. For example, in some embodiments, aerosol precursor compositions, such as glycerin and / or propylene glycol, may be used in the substrate material to generate a visible mainstream aerosol that resembles in many respects the appearance of cigarette smoke.

[0071] 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 embodiments, the substrate material is capable of generating a visible aerosol upon application of sufficient heat (and, if necessary, cooling with air), and the substrate material is capable of generating a "smoky" aerosol. In other embodiments, the substrate material is capable of generating 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 may vary depending on the specific components of the aerosol delivery component. The substrate material may be chemically simple compared to the chemistry of smoke generated by burning tobacco.

[0072] According to another embodiment, an aerosol delivery device 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 filled into the ceramic. In another embodiment, the substrate material may contain 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 that described above, may be porous. For example, in some embodiments, the extruded tobacco material may contain an inert gas, such as nitrogen, that acts as a foaming agent during the extrusion process.

[0073] As noted above, in some embodiments, one or more of the substrate materials may contain 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.

[0074] 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.

[0075] 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 flavoring ingredients and / or top layer 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 disclosures of which are incorporated herein by reference in their entireties. Preferred flavoring ingredients 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 contain top layer materials (e.g., flavoring materials 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 may 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.

[0076] A wide variety of flavors 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 flavors may be provided from sources other than tobacco and may be natural or artificial in nature. For example, some flavors may be applied to or incorporated into the substrate material and / or the area of ​​the smoking article where the aerosol is generated. In some embodiments, such flavors may be provided directly to the heating cavity or area 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 flavors and flavor packages of the type and characteristics conventionally used in cigarette, cigar, and pipe tobacco flavorings. Syrups, such as high fructose corn syrup, may also be suitable for use.

[0077] 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 the 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, aromas, and the like, that may be 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 substrate materials are described in U.S. Patent Application Publication No. 2015 / 0344456 to Dull et al., which is incorporated herein by reference in its entirety.

[0078] 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.

[0079] 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.

[0080] In the illustrated embodiment, the cross-section of the aerosol source member 200 may be generally circular, such that the aerosol source member 200 defines a generally cylindrical shape extending between its opposite first and second ends. However, in other embodiments, the aerosol source member 200 may define a substantially non-circular cross-section, such that the aerosol source member 200 may define a substantially non-cylindrical shape between its opposite first and second ends. Alternatively, in other examples, the aerosol source member 200 may include a cross-section that is asymmetric about an axis.

[0081] Although not shown, the housing 104 may include one or more apertures therein to allow the ingress of ambient air to be directed toward the heated end 202 of the aerosol source member 200. Thus, when a consumer draws on the mouth end 204 of the aerosol source member 200, air enters the aerosol source member 200 adjacent the heated end 202, is drawn through the inhalable substance medium, and can be inhaled by the consumer through the mouth end 204. As described in more detail below, in embodiments where an overwrap is present, the drawn air can carry the inhalable substance through an opening in the overwrap, through an optional filter, and out of the overwrap.

[0082] In some embodiments, the control body 102 may also include a flow sensor (not shown, e.g., a puff sensor or pressure switch). In other embodiments, the control body 102 may alternatively or additionally include an activation button (not shown). With respect to the flow sensor, representative current regulating components and other current control components, including various microcontrollers, sensors, and switches for aerosol delivery devices, are described in 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, all to Brooks et al., U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entireties. Reference is also made to the control scheme described in US Pat. No. 9,423,152 to Ampolini et al., which is incorporated herein by reference in its entirety.

[0083] Further components may be utilized in the aerosol delivery device of the present disclosure. For example, U.S. Patent No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article, U.S. Patent No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouth end of the device that detects a user's lip movement associated with drawing and then causes heating of the heating device, U.S. Patent No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow to a heat load array in response to a drop in pressure through a mouthpiece, U.S. Patent No. 5,967,148 to Harris et al. discloses a container within a smoking device that includes an identifier that detects non-uniformity in infrared transparency of an inserted component and a controller that executes a detection routine when a component is inserted into the container, U.S. Patent No. 6,040,560 to Fleischhauer et al. describes a defined, executable power cycle with multiple differential phases, and U.S. Patent No. 5,934,288 to Watkins et al. No. 9 discloses photonic-optronic components; U.S. Pat. No. 5,954,979 to Counts et al. discloses means for varying the resistance to draw through a smoking device; U.S. Pat. No. 6,803,545 to Blake et al. discloses particular battery configurations for use in smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses computer interface means for smoking devices to facilitate charging and enable computer control of the device; U.S. Pat. No. 8,689,804 to Fernando et al. discloses an identification system for smoking devices; and PCT Publication No. WO 2010 / 003480 to Flick discloses a fluid flow sensing system to indicate a puff using an aerosol generating system, all of the foregoing disclosures are incorporated herein by reference in their entireties.

[0084] Additional examples of components and disclosed materials or components associated with electronic aerosol delivery devices that can be used in the present article include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 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. 7,513,253 to Kobayashi, U.S. Pat. No. 7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. No. 6,772,756 to Hon, U.S. Pat. No. 6,832,410 to Hon, U.S. Pat. No. 6,832,410 to Hon, U.S. Pat. No. 6,513,253 to Kobayashi, U.S. Pat. No. 6,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. No. 6,772,756 to Hon, U.S. Pat. No. 6,832,410 to Hon, U.S. Pat. No. 6,832,410 to Hon, U.S. Pat. No. 6, Nos. 8,156,944 and 8,375,957 to Thorens et al., U.S. Pat. No. 8,794,231 to Thorens et al., U.S. Pat. No. 8,851,083 to Oglesby et al., U.S. Pat. Nos. 8,915,254 and 8,925,555 to Monsees et al., U.S. Pat. No. 9,220,302 to DePiano et al., U.S. Patent Application Publication No. 2006 / 019651 to Hon Examples of such aerosol delivery devices include U.S. Patent Application Publication No. 2009 / 0188490 to Oglesby et al., U.S. Patent Application Publication No. 2010 / 0024834 to Wang, U.S. Patent Application Publication No. 2010 / 0307518 to Hon, PCT International Publication No. 2010 / 091593 to Hon, and PCT International Publication No. 2013 / 089551 to Foo, each of which is incorporated herein by reference in its entirety. Furthermore, U.S. Patent Application No. 14 / 881,392 to Worm et al., filed October 13, 2015, discloses a capsule that can be included in an aerosol delivery device and a fob-shaped configuration for the aerosol delivery device, and is incorporated herein by reference in its entirety. In various embodiments, various materials disclosed by the aforementioned documents may be incorporated into the device, and all of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0085] In some embodiments, the aerosol delivery device may include an input element (which may replace or complement the airflow or pressure sensor). The input element may be included to allow a user to control device functions and / or output information to the user. Any component or combination of components may be utilized as an input element for controlling device functions. For example, one or more push buttons may be used, as described in U.S. Patent Application Publication No. 2015 / 0245658 to Worm et al., which is incorporated herein by reference. Similarly, a touchscreen may be used, as described in U.S. Patent Application No. 14 / 643,626 to Sears et al., filed March 10, 2015, which is incorporated herein by reference. As a further example, a component adapted for gesture recognition based on specific movements of the aerosol delivery device may be used as an input. See U.S. Patent Application Publication No. 2016 / 0158782 to Henry et al., which is incorporated herein by reference. As yet another example, a capacitance sensor may be implemented in the aerosol delivery device to allow a user to provide input, such as by touching a surface of the device on which the capacitance sensor is implemented.

[0086] As mentioned above, the aerosol delivery device 100 of the illustrated embodiment also includes a heating assembly 110 that receives power from an electrical energy source 108 and, in some embodiments, can be controlled by the control component 106. In various embodiments, the heating assembly 110 can include a heating element, which can be any device suitable for providing sufficient heat to facilitate release of the inhalable substance for inhalation by the consumer. In certain embodiments, the electrical heating element can be a resistive heating element. Useful heating elements can have low mass, low density, moderate resistivity, and be thermally stable at the temperatures experienced during use. Useful heating elements heat and cool rapidly, thereby efficiently using energy. Rapid heating of the element also results in nearly instantaneous volatilization of the aerosol-forming substance. Rapid cooling prevents substantial volatilization (and therefore waste) of the aerosol-forming substance during periods when aerosol formation is not desired. Such heating elements also allow for relatively precise control of the temperature range experienced by the aerosol-forming substance, especially when time-based current control is used. Useful heating elements are also chemically non-reactive (and chemically non-catalytic) with the materials comprising the inhalable substance medium being heated so as not to adversely affect the flavor or content of the aerosol or vapor produced. Exemplary, non-limiting materials from which the heating element may be constructed include various metals and ceramic materials. Other specific, non-limiting examples include carbon, graphite, carbon / graphite composites, metal and non-metal carbides, nitrides, silicides, intermetallic compounds, cermets, metal alloys, and metal foils. Refractory materials may be particularly useful. A variety of different materials can be blended to achieve desired properties of resistivity, mass, thermal conductivity, and surface properties.

[0087] In some embodiments, the heating element may be provided in other forms, such as in the form of a foil, foam, mesh, hollow sphere, hemisphere, disk, spiral, fiber, wire, film, thread, strip, ribbon, or cylinder. Such heating elements often comprise a metallic material and are configured to generate heat as a result of electrical resistance associated with passing an electric current through them. Such resistive heating elements may be positioned in proximity to and / or in direct contact with the substrate portion. As described in further detail below, the heating assembly or heating element may be disposed in the control body and / or the aerosol source member. In various embodiments, the substrate portion may include components embedded in or otherwise part of the substrate portion (i.e., thermally conductive components) that can function as or facilitate the function of the heating assembly. Some examples of various heating elements and heating elements are described in U.S. Pat. No. 9,078,473 to Worm et al., the disclosure of which is incorporated herein by reference in its entirety.

[0088] Some non-limiting examples of various heating member configurations include configurations in which the heating member or heating element is positioned proximate to the aerosol source member. For example, in some examples, at least a portion of the heating member may surround at least a portion of the aerosol source member. In other examples, one or more heating members may be positioned adjacent to the exterior of the aerosol source member when inserted into the control body. In other examples, at least a portion of the heating member may penetrate at least a portion of the aerosol source member when inserted into the control body (e.g., one or more protrusions and / or spikes that penetrate the aerosol source member, etc.).

[0089] Various embodiments of materials configured to generate heat upon application of an electric current may be used to form the heating element. Examples of materials from which the wire coil may be formed include Kanthal (FeCrAl), nichrome, nickel, stainless steel, indium tin oxide, tungsten, molybdenum disilicide (MoSi), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al)), titanium, platinum, silver, palladium, alloys of silver and palladium, graphite and graphite-based materials (e.g., carbon-based foams and yarns), conductive inks, boron-doped silica, and ceramics (e.g., positive or negative temperature coefficient ceramics). The heating element may be a resistive heating element or a heating element configured to generate heat by induction. The heating element may be coated with a thermally conductive ceramic, such as aluminum nitride, silicon carbide, beryllium oxide, alumina, silicon nitride, or a composite thereof.

[0090] As will be explained in more detail below, in some of the illustrated embodiments, multiple spikes function as the heating elements, while in other illustrated embodiments, multiple spaced bands function as the heating elements in addition to or as an alternative to multiple spikes.

[0091] As shown in FIG. 1 , the heating assembly 110 includes a plurality of spikes 112 configured to articulate between a retracted position in which the spikes are not in contact with the aerosol source member 200 and a heated position in which the spikes are in contact with the aerosol source member 200. In particular, FIG. 1 shows the spikes 112 in the heated position. In various embodiments of the heated position, the spikes not only contact the aerosol source member 200 but also penetrate the outer surface 206 of the aerosol source member 200 such that a portion of the spikes 112 extends into the substrate material 210. In various embodiments, the extent to which the spikes 112 extend into the substrate material may vary. For example, in some embodiments, the spikes 112 may extend only a small distance into the substrate material, while in other embodiments, the spikes 112 may extend to the center of the substrate material 210, and in still other embodiments, the spikes 112 may penetrate the center of the substrate material 210.

[0092] In various embodiments, the plurality of spikes 112 may comprise opposing rows of spikes 112, as shown in FIGS. 1 and 2, with one row disposed on one side of the aerosol source member 200 and the other row disposed on the opposite side of the aerosol source member 200. Note that in some embodiments, there may be additional rows of spikes 112, such as three or more rows that may be disposed around the circumference of the heated end 202 of the aerosol source member 200. However, in other embodiments, there may be a single row of spikes 112. In some embodiments, the positioning of the individual spikes 112 may be staggered between rows, as shown in FIGS. 1 and 2, while in other embodiments, the positioning of the individual spikes 112 may be substantially aligned. In various embodiments, articulation of the plurality of spikes 112 may occur in various ways. For example, in some embodiments, the plurality of spikes 112 may be housed in a clamshell housing that moves away from the aerosol source member 200 in a retracted position and toward the aerosol source member 200 in a heated position. In some embodiments, actuation of the articulation may be triggered by a button. For example, in some embodiments, the clamshell housing may be spring-loaded, and a button may trigger the clamshell housing to move from the retracted position to the heated position. In another embodiment, a user may slide a feature that moves one or both rows of spikes 112 from the retracted position to the heated position, where the spikes 112 penetrate the outer surface 206 of the substrate material and enter a portion of its interior region 208. It should be noted that, while in the illustrated embodiment, the spikes are shown schematically as having a substantially conical shape, in various other embodiments the spikes may have a variety of other shapes configured to allow the spikes to penetrate the aerosol source member, including, for example, a generally cylindrical shape, a generally prismatic shape, a generally cubical shape, etc.

[0093] In various embodiments, the heating element of the heating assembly 110 can generate heat upon receiving electrical energy from the electrical energy source 108. Thus, in some embodiments, the plurality of spikes 112 may comprise resistive heating elements that heat the substrate material 210 through contact with the substrate material 210. Because the plurality of spikes 112 extend into a portion of the interior region 208 of the substrate material 210, the substrate material 210 in the illustrated embodiment heats from the inside out. Direct contact may be preferred given its ability to provide conductive heating that is more rapid and requires less thermal resistance. In various embodiments, the plurality of spikes 112 may be constructed from a thermally conductive material. For example, in some embodiments, the plurality of spikes 112 is chemically non-reactive with materials comprising the substrate material being heated so as not to adversely affect the flavor or content of the aerosol or vapor being generated. As noted above, exemplary, non-limiting materials that may comprise the plurality of spikes 112 include carbon, graphite, carbon / graphite composites, metal and non-metal carbides, nitrides, silicides, intermetallic compounds, cermets, and metal alloys. In some embodiments, metal foils may be used.

[0094] In some embodiments, additional heating elements may be used. For example, some additional heating elements may have other shapes corresponding to the shape of the substrate material within the aerosol source element. Other examples of heater arrays that can be adapted for use in the present disclosure in accordance with the above description are described in U.S. Patent No. 5,060,671 to Counts et al., U.S. Patent No. 5,093,894 to Deevi et al., U.S. Patent No. 5,224,498 ... Sprinkel et al., which are incorporated herein by reference in their entireties. No. 5,322,075 to Deevi et al., U.S. Pat. No. 5,353,813 to Deevi et al., U.S. Pat. No. 5,468,936 to Deevi et al., U.S. Pat. No. 5,498,850 to Das, U.S. Pat. No. 5,659,656 to Das, U.S. Pat. No. 5,498,855 to Deevi et al., U.S. Pat. No. 5,530,225 to Hajaligol, U.S. Pat. No. 5,665,262 to Hajaligol, U.S. Pat. No. 5,573,692 to Das et al., and U.S. Pat. No. 5,591,368 to Fleischhauer et al.

[0095] FIG. 3 shows a perspective schematic view of a heated end 302 of an aerosol source member and a portion of a heating assembly according to another exemplary embodiment of the present disclosure. In particular, the heated end 302 of the aerosol source member defines an exterior surface 306 and an interior region 308. In the illustrated embodiment, a substrate material 310 is disposed in the interior region 308 of the heated end 302 of the aerosol source member. As noted above, in some embodiments, a substrate material may be disposed in both the heated end 302 and the mouth end of the aerosol source member. In the illustrated embodiment, the substrate material 310 has a single segment; however, in other embodiments, the substrate material 310 may include additional segments that may have different compositions. 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. Reference is made to possible substrate materials, compositions, ingredients and / or additives for use with the substrate material(s) described above.

[0096] As described above, heating of the substrate material 310 results in aerosolization of the aerosol precursor composition bound to the substrate material 310. In various embodiments, the mouth end of the aerosol source member is configured to receive the generated aerosol therethrough in response to suction applied to the mouth end by a user. In some embodiments, the mouth end of the aerosol source member may include a filter configured to receive the aerosol therethrough in response to suction applied to the mouth end of the aerosol source member. Preferably, the elements of the substrate material 310 do not significantly pyrolyze (e.g., char, scorch, or burn), and the aerosolized components are entrained in air, which is drawn through the aerosol delivery device 100, including the filter (if present), and into the user's mouth.

[0097] As shown in FIG. 3 , the heating assembly of the illustrated embodiment includes a plurality of spikes 112 configured to articulate between a retracted position in which the spikes are not in contact with the aerosol source member and a heated position in which the spikes are in contact with the aerosol source member. In particular, FIG. 3 shows the spikes 112 in the heated position. In various embodiments of the heated position, the spikes 112 not only contact the aerosol source member but also penetrate the outer surface 306 of the aerosol source member such that a portion of the spikes 112 extends into the substrate material 310. In various embodiments, the extent to which the spikes 112 extend into the substrate material may vary. For example, in some embodiments, the spikes 112 may extend only a small amount into the substrate material, while in other embodiments, the spikes 112 may extend to the center of the substrate material 310, and in still other embodiments, the spikes 112 may penetrate the center of the substrate material 310.

[0098] In various embodiments, the plurality of spikes 112 may comprise opposing rows of spikes 112, such as those shown in FIG. 3, with one row disposed on one side of the aerosol source member and the other row disposed on the opposite side of the aerosol source member. Note that in some embodiments, there may be additional rows of spikes 112, such as three or more rows that may be disposed around the circumference of the heated end 302 of the aerosol source member. However, in other embodiments, there may be a single row of spikes 112. In some embodiments, the positioning of the individual spikes 112 may be staggered between rows, such as that shown in FIG. 3, while in other embodiments, the positioning of the individual spikes 112 may be substantially aligned. As noted above, in various embodiments, articulation of the plurality of spikes 112 may occur in various ways. For example, in some embodiments, the plurality of spikes 112 may be housed in a clamshell housing that moves away from the aerosol source member in the retracted position and toward the aerosol source member in the heated position. In some embodiments, actuation of the articulation may be triggered by a button. For example, in some embodiments, the clamshell housing can be spring-loaded, and a button may be triggered to move the clamshell housing from a retracted position to a heated position. In another embodiment, a user may slide a feature that brings one or both rows of spikes 112 from a retracted position to a heated position, in which the spikes 112 pierce the outer surface of the substrate material and enter a portion of its interior region 308.

[0099] In various embodiments, the heating element of the heating assembly can generate heat upon receiving electrical energy from an electrical energy source. Thus, in some embodiments, the plurality of spikes 112 may comprise resistive heating elements that heat the substrate material 310 through a supplemental thermally conductive material in addition to contacting the substrate material 310. In the illustrated embodiment, the supplemental thermally conductive material comprises a plurality of spaced apart conductive bands 320. Thus, in addition to or as an alternative to heating the substrate material 310 through the spikes 112 themselves, the substrate material 310 may be heated by the plurality of spaced apart conductive bands 320 through thermal conduction from the plurality of spikes 112. In some embodiments, the plurality of conductive bands 320 may be constructed from a metallic material such as, but not limited to, copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, or any combination thereof. In other embodiments, the plurality of conductive bands 320 may be constructed from a coated metal, such as, for example, aluminum-coated copper, or other combinations of coatings and base materials selected from the list above. In still other embodiments, the plurality of conductive bands 320 may be constructed from a ceramic material, such as, but not limited to, aluminum oxide, beryllium oxide, boron nitride, silicon carbide, silicon nitride, aluminum nitride, or any combination thereof. In still other embodiments, the plurality of conductive bands 320 may be constructed from a carbon material, such as, but not limited to, graphite, graphene, carbon nanotubes, nanoribbons, diamond-like structured carbon materials, or combinations thereof. In still other embodiments, the plurality of conductive bands 320 may be constructed from a metal, ceramic, or polymer composite material, such as a polymer material including carbon fibers. For example, some embodiments may include polyimide, epoxy, or silicone polymers with boron nitride, zinc oxide, or alumina fibers. In further embodiments, the present disclosure contemplates that the plurality of conductive bands 320 may be constructed from any one or any combination of the above materials, or a composite material including two or more of the above materials.

[0100] FIG. 4 shows a perspective schematic view of the heated end 402 of the aerosol source member. FIG. 5 shows a perspective schematic view of the heated end 402 of the aerosol source member and a portion of the heating assembly. FIG. 6 shows a top schematic view of the heated end 402 of the aerosol source member and a portion of the heating assembly according to another exemplary embodiment of the present disclosure. In the illustrated embodiment, the heated end 402 of the aerosol source member defines a first exterior surface 406 and a first interior region 408, and a first substrate material 410 is disposed in the first interior region 408 of the heated end 402 of the aerosol source member. As noted above, in some embodiments, a substrate material may be disposed in both the heated end 402 and the mouth end of the aerosol source member. In the illustrated embodiment, the first substrate material 410 has a single segment, but in other embodiments, the first substrate material 410 may include additional segments that can have different compositions. In various embodiments, the first substrate material 410 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. Possible substrate materials, compositions, ingredients, and / or additives for use with the substrate material(s) described above are mentioned.

[0101] The illustrated embodiment also includes a second substrate material 412 that substantially surrounds the first substrate material 410. Notably, the second substrate material 412 in the illustrated embodiment is disposed near the first outer surface 406 of the first substrate material 410 and defines its own second outer surface 416 and a second interior region 418. Like the first substrate material 410, in the illustrated embodiment, the second substrate material 412 has a single segment; however, in other embodiments, the second substrate material 412 may include additional segments that may have different compositions. In various embodiments, the second substrate material 412 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. Possible substrate materials, compositions, ingredients, and / or additives for use with the substrate material(s) described above are discussed. In some embodiments, the first substrate material 410 and the second substrate material 412 may contain the same material, while in various other embodiments, the first substrate material 410 and the second substrate material 412 may contain different materials. For example, in some embodiments, the first substrate material 410 and the second substrate material 412 may include one or more respective components that are desired to be kept separate. For example, in one embodiment, one substrate material may contain an ionized calcium (e.g., Ca++) component and the other substrate material may contain an alginate component.

[0102] As described above, heating the first substrate material 410 and / or the second substrate material 412 results in aerosolization of the aerosol precursor composition bound to the substrate materials 410, 412. In various embodiments, the mouth end of the aerosol source member is configured to receive the generated aerosol therethrough in response to suction applied to the mouth end by a user. In some embodiments, the mouth end of the aerosol source member may include a filter configured to receive the aerosol therethrough in response to suction applied to the mouth end of the aerosol source member. Preferably, the elements of the substrate materials 410, 412 do not significantly pyrolyze (e.g., char, scorch, or burn), and the aerosolized components are entrained in air, which is drawn through the aerosol delivery device 100, including the filter (if present), and into the user's mouth.

[0103] As shown in FIGS. 5 and 6 , the heating assembly of the illustrated embodiment includes a plurality of spikes 112 configured to articulate between a retracted position in which the spikes 112 are not in contact with the aerosol source member and a heated position in which the spikes 112 are in contact with the aerosol source member. In particular, FIGS. 5 and 6 show the spikes 112 in the heated position. In various embodiments of the heated position, the spikes 112 not only contact the aerosol source member but also penetrate the second outer surface 416 of the aerosol source member such that a portion of the spikes 112 extends into the second substrate material 412. In some embodiments, the spikes 112 extend only into the second substrate material 412 and not into the first substrate material 410. In such embodiments, the distance the spikes 112 extend into the second substrate material 412 can be varied. For example, in some embodiments, the spikes 112 may extend only a small distance into the second substrate material 412, while in other embodiments, the spikes 112 may extend to the center of the second substrate material 412, and in still other embodiments, the spikes 112 may penetrate all the way through the second substrate material 412. In the illustrated embodiment, the spikes 112 penetrate the second substrate material 412 and further extend through the first outer surface 406 into the first substrate material 410. In such embodiments, the extent to which the spikes 112 extend into the first substrate material 410 may vary. For example, in some embodiments, the spikes 112 may extend only a small distance into the first substrate material 410, while in other embodiments, the spikes 112 may extend all the way through the center of the first substrate material 410, and in still other embodiments, the spikes 112 may penetrate all the way through the center of the first substrate material 410.

[0104] In various embodiments, the plurality of spikes 112 may comprise opposing rows of spikes 112, such as those shown in FIG. 5, with one row disposed on one side of the aerosol source member and the other row disposed on the opposite side of the aerosol source member. Note that in some embodiments, there may be additional rows of spikes 112, such as three or more rows that may be disposed around the circumference of the heated end 402 of the aerosol source member. However, in other embodiments, there may be a single row of spikes 112. In some embodiments, the positioning of the individual spikes 112 may be staggered between rows, such as that shown in FIG. 5, while in other embodiments, the positioning of the individual spikes 112 may be substantially aligned. As noted above, in various embodiments, articulation of the plurality of spikes 112 may occur in various ways. For example, in some embodiments, the plurality of spikes 112 may be housed in a clamshell housing that moves away from the aerosol source member in the retracted position and toward the aerosol source member in the heated position. In some embodiments, actuation of the articulation may be triggered by a button. For example, in some embodiments, the clamshell housing may be spring loaded and a button may be triggered to move the clamshell housing from a retracted position to a heated position. In another embodiment, a user may slide a feature that brings one or both rows of spikes 112 from a retracted position to a heated position, in which the spikes 112 pierce the outer surface of the substrate material and enter a portion of its interior region 408.

[0105] As described above, in various embodiments, the heating elements of the heating assembly can generate heat upon receiving electrical energy from an electrical energy source. Thus, in some embodiments, the plurality of spikes 112 may comprise resistive heating elements that heat the first and second substrate materials 410, 412 through a supplemental thermally conductive material in addition to contact with the substrate materials 410, 412 themselves. In the illustrated embodiment, the supplemental thermally conductive material comprises a plurality of spaced apart conductive bands 420 disposed between the first outer surface 406 of the first substrate material 410 and the inner surface of the second substrate material 412. Thus, in addition to, or as an alternative to, heating the first and second substrate materials 410, 412 through the spikes 112 themselves, the first and second substrate materials 410, 412 may be heated by the plurality of spaced apart conductive bands 420 through thermal conduction from the plurality of spikes 112. In some embodiments, the plurality of spaced apart conductive bands 420 may be constructed from a metallic material such as, but not limited to, copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, or any combination thereof. In other embodiments, the plurality of conductive bands 420 may be constructed from a coated metal, such as, for example, aluminum-coated copper, or other combinations of coating and base materials selected from the list above. In still other embodiments, the plurality of spaced apart conductive bands 420 may be constructed from a ceramic material such as, but not limited to, aluminum oxide, beryllium oxide, boron nitride, silicon carbide, silicon nitride, aluminum nitride, or any combination thereof. In still other embodiments, the plurality of thermally conductive bands 420 may be constructed from a carbon material such as, but not limited to, graphite, graphene, carbon nanotubes, nanoribbons, diamond-like structured carbon materials, or combinations thereof. Additionally, in still other embodiments, the plurality of thermally conductive bands 420 may be constructed from polymer composite materials such as polymer materials containing metal, ceramic, or carbon fibers, including, but not limited to, polyimide, epoxy, or silicone polymers, along with boron nitride, zinc oxide, or alumina fibers.In further embodiments, the present disclosure contemplates that the multiple conductive bands may be constructed from any one or any combination of the above materials, or a composite material including two or more of the above materials.

[0106] Note that in the illustrated embodiment, the substrate material is present below and between the conductive bands, but in other embodiments, the aerosol source material may be present only below the conductive bands, or in other embodiments, only between the conductive bands. Furthermore, in the illustrated embodiment, the concentration of aerosol-forming material in the substrate material is relatively constant throughout the segments, but in some embodiments, the concentration of aerosol-forming material in the substrate material may vary from segment to segment.

[0107] FIG. 7 shows a perspective schematic view of a portion of the heated end 502 of the aerosol source member and a portion of the heating assembly, and FIG. 8 shows a top schematic view of the heated end 502 of the aerosol source member and a portion of the heating assembly, according to an exemplary embodiment of the present disclosure. In particular, the heated end 502 of the aerosol source member defines a first exterior surface 506 and a first interior region 508, and a first substrate material 510 is disposed in the first interior region 508 of the heated end 502 of the aerosol source member. As noted above, in some embodiments, a substrate material may be disposed in both the heated end 502 and the mouth end of the aerosol source member. In the illustrated embodiment, the first substrate material 510 has a single segment, but in other embodiments, the first substrate material 510 may include additional segments that may have different compositions. In various embodiments, the first substrate material 510 may include tobacco or a tobacco-related material with an aerosol precursor composition bound thereto. In other embodiments, a non-tobacco material, such as a cellulose pulp material, may be used. In other embodiments, the non-tobacco substrate material may not be a plant-derived material. Reference is made to possible substrate materials, compositions, ingredients and / or additives for use with the substrate material(s) described above.

[0108] The illustrated embodiment also includes a second substrate material 512 that substantially surrounds the first substrate material 510. Notably, the second substrate material 512 in the illustrated embodiment is disposed near the first outer surface 506 of the first substrate material 510 and defines its own second outer surface 516 and a second interior region 518. Like the first substrate material 510, in the illustrated embodiment, the second substrate material 512 has a single segment; however, in other embodiments, the second substrate material 510 may include additional segments that may have different compositions. In various embodiments, the second substrate material 512 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. Possible substrate materials, compositions, ingredients, and / or additives for use with the substrate material(s) are discussed above. In some embodiments, the first substrate material 510 and the second substrate material 512 may contain the same material, while in various other embodiments, the first substrate material 510 and the second substrate material 512 may contain different materials. For example, in some embodiments, the first substrate material 510 and the second substrate material 512 may include one or more respective components that are desired to be kept separate. For example, in one embodiment, one substrate material may include an ionized calcium (e.g., Ca++) component and the other substrate material may include an alginate component.

[0109] As described above, heating the first substrate material 510 and / or the second substrate material 512 results in aerosolization of the aerosol precursor composition bound to the substrate materials 510, 512. In various embodiments, the mouth end of the aerosol source member is configured to receive the generated aerosol therethrough in response to suction applied to the mouth end by a user. In some embodiments, the mouth end of the aerosol source member may include a filter configured to receive the aerosol therethrough in response to suction applied to the mouth end of the aerosol source member. Preferably, the elements of the substrate materials 510, 512 do not significantly pyrolyze (e.g., char, scorch, or burn), and the aerosolized components are entrained in air, which is drawn through the aerosol delivery device 100, including the filter (if present), and into the user's mouth.

[0110] As shown in FIGS. 7 and 8 , the heating assembly of the illustrated embodiment includes a plurality of spikes 112 configured to articulate between a retracted position in which the spikes 112 are not in contact with the aerosol source member and a heated position in which the spikes 112 contact a plurality of spaced-apart conductive bands 520 extending around a limited portion of the outer surface of the first substrate material 510. In particular, FIGS. 7 and 8 show the spikes 112 in the heated position. In the illustrated embodiment, the plurality of spaced-apart conductive bands 520 function as heating elements. In particular, each of the plurality of spaced-apart conductive bands 520 of the illustrated embodiment defines a first end 520 a and a second end 520 b. In this manner, when the plurality of spikes 112, electrically connected to the electrical energy source 108, contact the first and second ends 520 a, 520 b of each of the plurality of spaced-apart conductive bands 520, a plurality of resistive heating circuits are completed, resulting in the plurality of spaced-apart conductive bands 520 functioning as heating elements.

[0111] In some embodiments, the plurality of spaced apart conductive bands 520 may be constructed from a metallic material such as, but not limited to, copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, or any combination thereof. In other embodiments, the plurality of conductive bands 520 may be constructed from a coated metal, such as, for example, aluminum-coated copper, or other combinations of coating and base materials selected from the list above. In still other embodiments, the plurality of spaced apart conductive bands 520 may be constructed from a ceramic material such as, but not limited to, aluminum oxide, beryllium oxide, boron nitride, silicon carbide, silicon nitride, aluminum nitride, or any combination thereof. In still other embodiments, the plurality of thermally conductive bands 520 may be constructed from a carbon material such as, but not limited to, graphite, graphene, carbon nanotubes, nanoribbons, diamond-like structured carbon materials, or combinations thereof. Also, in still other embodiments, the plurality of thermally conductive bands 520 may be constructed from a polymer composite material, such as a polymer material including metal, ceramic, or carbon fibers, including, but not limited to, polyimide, epoxy, or silicone polymers, along with boron nitride, zinc oxide, or alumina fibers. In further embodiments, the present disclosure contemplates that the plurality of conductive bands may be constructed from any one or any combination of the above materials, or a composite material including two or more of the above materials.

[0112] In some embodiments of the heated position, the spike 112 not only contacts the aerosol source member, but also penetrates the second outer surface 516 of the aerosol source member such that a portion of the spike 112 extends into the second substrate material 512. In some embodiments, the spike 112 extends only into the second substrate material 512 and not into the first substrate material 510. In such embodiments, the distance the spike 112 extends into the second substrate material 512 may vary. For example, in some embodiments, the spike 112 may extend only a small distance into the second substrate material 512, while in other embodiments the spike 112 may extend all the way to the center of the second substrate material 512, and in still other embodiments the spike 112 may penetrate all the way through the second substrate material 512. For example, in the illustrated embodiment, the spikes 112 extend through the second substrate material 512 and further through the first outer surface 506 into the first substrate material 510. In such embodiments, the extent to which the spikes 112 extend into the first substrate material 510 may vary. For example, in some embodiments, the spikes 112 may extend only a small distance into the first substrate material 510, while in other embodiments the spikes 112 may extend to the center of the first substrate material 510, and in still other embodiments the spikes 112 may penetrate the center of the first substrate material 510.

[0113] In various embodiments, the plurality of spikes 112 may comprise paired rows of spikes 112, such as those shown in FIG. 7, with one row positioned adjacent to the other row on the same side of the aerosol source member. In the illustrated embodiment, the rows of spikes 112 are substantially aligned. However, in other embodiments, such as embodiments in which the spaced-apart conductive bands have a spiral pattern around the substrate material, the rows of spikes may be staggered. Note, however, that for any of the embodiments described herein, the plurality of spikes need not be arranged in a pattern; thus, in some embodiments, the plurality of spikes may be randomly distributed. As noted above, in various embodiments, articulation of the plurality of spikes 112 can occur in various ways. For example, in some embodiments, the plurality of spikes 112 may be housed in a clamshell housing that moves away from the aerosol source member in a retracted position and toward the aerosol source member in a heated position. In some embodiments, actuation of the articulation may be triggered by a button. For example, in some embodiments, the clamshell housing may be spring loaded and a button may be triggered to move the clamshell housing from a retracted position to a heated position. In another embodiment, a user may slide a feature that brings one or both rows of spikes from a retracted position to a heated position, in which the thermally conductive spikes 112 penetrate the outer surface of the substrate material and enter a portion of its interior region 508.

[0114] For any of the above embodiments, the control component 106 and / or the plurality of spikes 112 may be configured to allow the substrate material (e.g., the first substrate material or the first and second substrate materials) to be heated in segments. In this manner, the plurality of spikes 112 may be configured to be independently controllable. For example, in some embodiments, individual spikes 112, pairs of spikes 112, and / or groups of spikes 112 may be independently controllable such that various portions of the substrate material can be heated at different times. In one embodiment, individual spikes 112, pairs of spikes 112, and / or groups of spikes 112 may be independently actuated (e.g., independently articulated and / or independently heated and / or independently connected to an electrical energy source) such that the substrate material is heated sequentially. This may occur via heating from the spikes and / or conductive bands, as described above. In various embodiments, actuation of spike 112 may be initiated by a consumer's puff action through the use of one or more various sensors, as described elsewhere herein, and / or may be initiated when a puff ceases as sensed by one or more various sensors, e.g., a button. Thus, in some embodiments, the number of possible heating segments may correspond to the number of puffs available from aerosol source member 200. In some embodiments, a single aerosol source member may provide about 4 to about 12 puffs, about 5 to about 11 puffs, or about 6 to about 10 puffs.

[0115] It should be noted that while the aerosol source member and control body of the present disclosure may generally be provided together as a complete smoking article or medication delivery article, the components may also be provided separately. For example, the present disclosure also encompasses disposable units for use with reusable smoking articles or reusable medication delivery articles. In certain embodiments, such a disposable unit (which may be an aerosol source member as shown in the accompanying figures) may include a substantially tubular body having a heated end configured to engage the reusable smoking article or medication delivery article, an opposing mouth end configured to allow passage of an inhalable substance to a consumer, and a wall having outer and inner surfaces defining an interior space. Various embodiments of aerosol source members (or cartridges) are described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference.

[0116] The present disclosure can be further characterized as providing a separate control body for use with a reusable smoking article or a reusable medication delivery article, in addition to the disposable unit. In certain embodiments, the control body can generally be a housing having a receiving end (which may include a receiving chamber with an open end) for receiving the heated end of a separately provided aerosol source member. The control body may further include a source of electrical energy for powering an electric heating element, which may be a component of the control body or may be included in an aerosol source element used with the control unit. In various embodiments, the control body may also include additional components, including a power source (such as a battery), a component for activating the flow of electrical current to the heating element, and a component for regulating such current flow to maintain a desired temperature for a desired period of time and / or to cycle or stop the flow of current when the desired temperature is reached or the heating element has been heating for a desired length of time. In some embodiments, the control unit may further include one or more push buttons associated with one or both of the components for activating the flow of electrical current to the heating element and a component for regulating such current flow. The control body may also include one or more indicators, such as a light that indicates that the heater is heating and / or a light that indicates the number of puffs remaining on an aerosol source member used with the control body.

[0117] Although the various figures described herein show the control body and aerosol source member in an operative relationship, it should be understood that the control body and aerosol source member may exist as separate devices, and therefore any description provided elsewhere herein regarding combined components should be understood as applying to the control body and aerosol source member as individual and separate components.

[0118] In another aspect, the present disclosure may be directed to kits providing various components described herein. For example, the kit may include a control body having one or more aerosol source members. The kit may further include a control body having one or more charging components. The kit may further include a control body having one or more batteries. The kit may further include a control body having one or more aerosol source members and one or more charging components and / or one or more batteries. In further embodiments, the kit may include multiple aerosol source members. The kit may further include multiple aerosol source members and one or more batteries and / or one or more charging components. In the above embodiments, the aerosol source member or control body may include a heating element included therein. The kits of the present invention may further include a case (or other packaging, transport, or storage component) for housing one or more of the additional kit components. The case may be a reusable hard or soft container. Additionally, the case may simply be a box or other packaging structure.

[0119] 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. 1. An aerosol source member for use with an aerosol delivery device, the aerosol source member comprising: The exterior and a first substrate material having an aerosol precursor composition bound thereto; a plurality of spaced apart thermally conductive bands; Equipped with the plurality of spaced apart thermally conductive bands are configured to heat the first substrate material via the aerosol delivery device; The aerosol source member includes a plurality of spaced apart thermally conductive bands, each extending around a limited portion of the first substrate material and defining a first end and a second end.

2. 10. The aerosol source member of claim 1, wherein the plurality of spaced apart thermally conductive bands heat the substrate material via thermal conduction through the aerosol delivery device.

3. 10. The aerosol source member of claim 1, wherein the plurality of spaced apart thermally conductive bands are substantially evenly spaced from one another.

4. 10. The aerosol source member of claim 1, further comprising a second substrate material, the second substrate material defining an outer surface and an interior region, the second substrate material surrounding the first substrate material.

5. 5. The aerosol source member of claim 4, wherein the plurality of spaced apart thermally conductive bands are located on an outer surface of the first substrate material.

6. 5. The aerosol source member of claim 4, wherein the plurality of spaced apart thermally conductive bands are located on an outer surface of the second substrate material.

7. 5. The aerosol source member of claim 4, wherein the first substrate material comprises a first composition and the second substrate material comprises a second composition, the first composition being different from the second composition.

8. 10. The aerosol source member of claim 1, wherein the plurality of spaced apart thermally conductive bands are constructed from a metallic material.

9. 9. The aerosol source member of claim 8, wherein the metal material comprises one or more of a copper material, an aluminum material, a platinum material, a gold material, a silver material, an iron material, a steel material, a brass material, a bronze material, or any combination thereof.

10. 10. The aerosol source member of claim 1, wherein the plurality of spaced apart thermally conductive bands are constructed from a coated metallic material.

11. 10. The aerosol source member of claim 1, wherein the plurality of thermally conductive bands are constructed of a ceramic material.

12. 12. The aerosol source member of claim 11, wherein the ceramic material comprises one or more of an aluminum oxide material, a beryllium oxide material, a boron nitride material, a silicon carbide material, a silicon nitride material, an aluminum nitride material, or any combination thereof.

13. 10. The aerosol source member of claim 1, wherein the plurality of spaced apart thermally conductive bands are constructed from a carbon material.

14. 14. The aerosol source member of claim 13, wherein the carbon material comprises a graphite material, a graphene material, carbon nanotubes, nanoribbons, diamond-like structured carbon material, or any combination thereof.

15. 10. The aerosol source member of claim 1, wherein the plurality of spaced apart thermally conductive bands are constructed from a polymer composite material.

16. 16. The aerosol source member of claim 15, wherein the polymer composite material comprises a polymer material having one or more of metal fibers, ceramic fibers, carbon fibers, or any combination thereof.

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