Powered Aerosol Delivery System

Abstract

To provide an electrically powered aerosol delivery system that is capable of allowing a user to inhale highly flavorful aerosol.SOLUTION: A cartridge body portion 200 includes a second tubular member 216 having opposed first and second ends. One of the first and second ends is removably engaged with one end of a control body portion. The cartridge body portion further comprises a first aerosol generation arrangement 212 disposed in the second tubular member and configured to operably engage a power source with an engagement portion between the control body portion and the cartridge body portion. A second aerosol generation arrangement 400 is disposed between the first aerosol generation arrangement and a mouth-engaging end of the aerosol delivery system, and is either removably engaged with the cartridge body portion or housed in the second tubular member of the cartridge body portion.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The disclosure relates to aerosol delivery devices and systems, such as smoking articles, and more particularly to aerosol delivery devices and systems that utilize electrically generated heat for aerosol products (smoking articles commonly referred to as e-cigarettes). The aerosol delivery devices and systems may be configured to heat an aerosol precursor, which may be made from or derived from tobacco, or incorporates a material that may, but need not, incorporate tobacco, and is vaporizable to form an aerosol that can be inhaled by a person. [Background technology]

[0002] Many smoking devices have been proposed for many years as an improvement or replacement for smoking products that require burning tobacco for use.Many of these devices are said to be designed to provide the sensation associated with cigarettes, cigars, or pipes without delivering a significant amount of incomplete combustion and pyrolysis products from burning tobacco.To achieve this goal, many smoking products, flavor generators, and medicinal inhalers have been proposed that utilize electrical energy to evaporate or heat volatile substances, or that attempt to provide the sensation of cigarettes, cigars, or pipes without burning tobacco to a significant extent.For example, see the various alternative smoking articles, aerosol delivery devices, and heat sources described in the background art of U.S. Patent No. 7,726,320 by Robinson et al., U.S. Patent Application No. 2013 / 0255702 by Griffith, Jr. et al., and U.S. Patent Application Publication No. 2014 / 0096781 by Sears et al., which are incorporated herein by reference. See also, for example, the various types of smoking articles, aerosol delivery devices, and electrically powered heat sources referenced by brand name and commercial source in U.S. Patent Application No. 14 / 170,838, filed February 3, 2014, by Bless et al., which is incorporated herein by reference.

[0003] It would be desirable to provide a powered aerosol delivery system that allows a user to inhale a highly flavorful aerosol, and it may also be desirable for the aerosol to be presented in a pleasant and comfortable manner when inhaled into the user's mouth. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] U.S. Patent Application No. 7,726,320 [Patent Document 2] US Patent Application Publication No. 2013 / 0255702 [Patent Document 3] US Patent Application Publication No. 2014 / 0096781 [Patent Document 4] U.S. Patent Application Serial No. 14 / 170,838 Summary of the Invention

[0005] The present disclosure relates to aerosol delivery systems. Such systems can generate aerosol as a result of heat generated by electrical power and deliver the aerosol to be inhaled into the user's mouth. Of particular importance to aerosol delivery systems is providing tobacco components in aerosol form, such as that provided to smokers by devices known or characterized as e-cigarettes. As used herein, the term "aerosol" is intended to include vapor, gas, aerosol, and / or particulate forms or types suitable for human inhalation, whether visible or invisible, and whether or not considered "smoke-like."

[0006] The above and other needs are met in one aspect by an embodiment of the present disclosure, which provides an aerosol delivery system. Such an aerosol delivery system may include a control body including a first elongated tubular member having opposing ends and having a power source disposed therein. The cartridge body includes a second tubular member having opposing first and second ends. One of the first and second ends of the cartridge body is removably engaged with one of the opposing ends of the control body. The cartridge body further includes a first aerosol generating device disposed within the second tubular member, configured to operably engage the power source with an engagement portion between one of the opposing ends of the control body and one of the first and second ends of the cartridge body. The other of the first and second ends of the cartridge body is further configured as a mouth-engagement end. The cartridge body further includes a second aerosol generating device within a second tubular member disposed between the first aerosol generating device and the mouth-engagement end. In some embodiments, the second aerosol generating device may further comprise one or more aerosol generating elements, and the one or more (at least one) aerosol generating elements may be selected from the group consisting of granules, pellets, beads, small discrete units, carbon pieces, extruded carbon pieces, ceramic beads, marmerized tobacco pieces, extruded or compressed cylindrical or spherical elements, ground tobacco flakes, fillers, flavors, visible aerosol-forming materials, binders, oval elements, irregularly shaped elements, fine fragments, flakes, tobacco-containing elements, visible aerosol-forming material-containing elements, adsorbent materials, absorbent materials, capsules, microcapsules, honeycomb monoliths, single porous structures, and combinations thereof.

[0007] Another aspect of the present disclosure provides a method for forming an aerosol delivery system, comprising: a first elongated tubular member having one end detachably engaged with a first end of a second tubular member, the first elongated tubular member configured as a control body having a power source disposed therein; and a second tubular member configured as a cartridge body having a first aerosol generation device disposed therein, the first aerosol generation device configured to operably engage the power source with an engagement portion between the one end of the control body and the first end of the cartridge body. The method also includes inserting a second aerosol generation device into the second tubular member of the cartridge body between the first aerosol generation device and the second end of the second tubular member, the second end opposing the first end and configured as a mouth-engagement end. In some cases, inserting the second aerosol-generating device into the second tubular member may further comprise forming one or more aerosol-generating elements within the second tubular member to at least partially form the second aerosol-generating device, wherein the one or more (at least one) aerosol-generating elements are selected from the group consisting of granules, pellets, beads, small discrete units, carbon flakes, extruded carbon flakes, ceramic beads, marmerized tobacco flakes, extruded or compressed cylindrical or spherical elements, ground tobacco flakes, fillers, flavorings, visible aerosol-forming materials, binders, oval elements, irregularly shaped elements, shreds, flakes, tobacco-containing elements, visible aerosol-forming material-containing elements, adsorbent materials, absorbent materials, capsules, microcapsules, honeycomb monoliths, single porous structures, and combinations thereof. As such, the present disclosure includes, but is not limited to, the following embodiments.

[0008] Embodiment 1 an aerosol delivery system comprising: a control body portion including a first elongated tubular member having opposing ends; a power source disposed therein; and a cartridge body portion including a second tubular member having opposing first and second ends, one of the first and second ends being detachably engageable with one of the opposing ends of the control body portion; the cartridge body portion further comprising a first aerosol generation device disposed within the second tubular member, the power source configured to operably engage in engagement between one of the opposing ends of the control body portion and one of the first and second ends of the cartridge body portion; the other of the first and second ends of the cartridge body portion being further optionally configured as a mouth engagement end; and the cartridge body portion further comprising a second aerosol generation device within the second tubular member disposed between the first aerosol generation device and the mouth engagement end.

[0009] Embodiment 2 The aerosol delivery system of any of the above or below embodiments, or combinations thereof, wherein the second aerosol generating device further comprises at least one aerosol generating element.

[0010] Embodiment 3 The aerosol delivery system of any of the preceding or following embodiments, or combinations thereof, wherein at least one aerosol-generating element is selected from the group consisting of granules, pellets, beads, small discrete units, carbon pieces, extruded carbon pieces, ceramic beads, marmerized tobacco pieces, extruded or compressed cylindrical or spherical elements, ground tobacco flakes, fillers, flavors, visible aerosol-forming materials, binders, oval elements, irregularly shaped elements, fine pieces, flakes, tobacco-containing elements, visible aerosol-forming material-containing elements, adsorbent materials, absorbent materials, capsules, microcapsules, honeycomb monoliths, single porous structures, and combinations thereof.

[0011] Embodiment 4 The aerosol delivery system of any of the preceding or following embodiments, or combinations thereof, further comprising a first separation element disposed within the second tubular member between the first aerosol generation device and the second aerosol generation device, wherein the first separation element is either thermally conductive and gas permeable.

[0012] Embodiment 5 The aerosol delivery system of any of the above or below embodiments, or a combination thereof, wherein the first separation element extends along the longitudinal axis between opposing ends to define a thickness, the thickness of the first separation element being configured to space the second aerosol generation device from the heating element of the first aerosol generation device.

[0013] Embodiment 6 The aerosol delivery system of any of the preceding or following embodiments, or combinations thereof, further comprising a second separation element disposed within the second tubular member between the second aerosol generation device and the mouth engagement end, wherein the second separation element is either thermally conductive and gas permeable.

[0014] Embodiment 7 The aerosol delivery system of any of the preceding or following embodiments, or a combination thereof, wherein the second aerosol generation device comprises a cartridge having an elongated tubular body and opposing end members, each of the end members being either thermally conductive or gas permeable, the elongated tubular body being further configured to receive at least one aerosol generating element and cooperate with the opposing end members to house the at least one aerosol generating element therein, and the cartridge being configured to be received by the second tubular member.

[0015] Embodiment 8 The aerosol delivery system of any of the preceding or following embodiments, or a combination thereof, wherein the first aerosol generating device comprises a liquid container disposed within the second tubular member and configured to receive an aerosol precursor material used by the first aerosol generating device to generate the first aerosol.

[0016] Embodiment 9 The aerosol delivery system of any of the preceding or following embodiments, or combinations thereof, wherein the aerosol precursor material is one of flavorless and acid-free.

[0017] Embodiment 10 The aerosol delivery system of any of the preceding or following embodiments, or combinations thereof, wherein the aerosol precursor material is one of glycerin, propylene glycol, water, saline, nicotine, an organic acid, and combinations thereof.

[0018] Embodiment 11 The aerosol delivery system of any of the preceding or following embodiments, or a combination thereof, wherein the first aerosol generation device is configured to provide heat to generate the first aerosol, and the second aerosol generation device includes at least one aerosol generating element, the at least one aerosol generating element being arranged to interact with the first aerosol drawn through the aerosol generating element and into the mouth engaging end in response to heat and suction applied to the mouth engaging end of the cartridge body.

[0019] Embodiment 12 The aerosol delivery system of any of the preceding or following embodiments, or a combination thereof, wherein at least one aerosol generation element of the second aerosol generation device is configured to interact with heat from the heating element of the first aerosol generation device and either the first aerosol generated by the first aerosol generation device to generate the second aerosol.

[0020] Embodiment 13 The aerosol delivery system of any of the preceding or following embodiments, or a combination thereof, wherein a first aerosol generated by the first aerosol generating device is configured to interact with a second aerosol generated by the second aerosol generating device to form a third aerosol that is drawn into the mouth engaging end in response to suction applied to the mouth engaging end.

[0021] Embodiment 14 The aerosol delivery system of any of the preceding or following embodiments, or a combination thereof, wherein at least one aerosol generating element of the second aerosol generating device is configured to interact with and impart an enhancing substance to the first aerosol generated by the first aerosol generating device to generate an enhanced aerosol that is drawn into the mouth engaging end in response to suction applied to the mouth engaging end.

[0022] Embodiment 15 The aerosol delivery system of any of the preceding or following embodiments, or a combination thereof, wherein at least one aerosol generating element of the second aerosol generating device is configured to interact with and remove heat from the first aerosol generated by the first aerosol generating device to generate a cooled aerosol that is drawn into the mouth engaging end in response to suction applied to the mouth engaging end.

[0023] Embodiment 16 an aerosol delivery system comprising: a control body portion including a first elongated tubular member having opposing ends and a power source disposed therein; a cartridge body portion including a second tubular member having opposing first and second ends, the first end engaging one of the opposing ends of the control body portion; a first aerosol generation device disposed within the second tubular member, the power source configured to operably engage an engagement portion between one of the opposing ends of the control body portion and the first end of the cartridge body portion, the second end of the cartridge body portion toward a mouth engagement end of the aerosol delivery system; and a second aerosol generation device disposed between the first aerosol generation device and the mouth engagement end of the aerosol delivery system, the second aerosol generation device removably engaging with the cartridge body portion or housed within the second tubular member of the cartridge body portion.

[0024] Embodiment 17 The aerosol delivery system of any of the preceding or following embodiments, wherein the second aerosol-generating device further comprises a plurality of aerosol-generating elements in the form of beads or pellets comprising at least one aerosol-forming material.

[0025] Embodiment 18 The aerosol delivery system of any of the preceding or following embodiments, wherein the aerosol-generating element further comprises one or more of granular tobacco, tobacco extract, and nicotine, wherein the nicotine is in free base form, a salt form, a complex, or a solvate.

[0026] Embodiment 19 The aerosol delivery system of any of the above or below embodiments, wherein the aerosol-generating element further comprises one or more fillers, binders, flavorings, and combinations thereof.

[0027] Embodiment 20 The aerosol delivery system of any of the preceding or following embodiments, wherein the aerosol-generating element is smoked.

[0028] Embodiment 21 The aerosol delivery system of any of the preceding or following embodiments, wherein the second aerosol generation device is contained within the second tubular member of the cartridge body, and includes a plurality of aerosol generation elements in the form of beads or pellets held in place by a first air-permeable separation element disposed within the second tubular member between the first aerosol generation device and the second aerosol generation device, and a second separation element between the second aerosol generation device and the mouth-engaging end.

[0029] Embodiment 22 The aerosol delivery system of any of the preceding or following embodiments, wherein the second aerosol generation device is removably engaged with the cartridge body portion and includes a plurality of aerosol generation elements in the form of beads or pellets held in place by a first air-permeable separation element between the first aerosol generation device and the second aerosol generation device, and a second separation element between the second aerosol generation device and the mouth-engagement end.

[0030] Embodiment 23 A method of forming an aerosol delivery system, comprising: inserting a second aerosol generating device into the second tubular member of the cartridge body between the first aerosol generating device and the second end of the second tubular member; the first aerosol generating element having one end of the first elongated tubular member detachably engaging with the first end of the second tubular member; the second end being opposite the first end and configured as a mouth engagement end; and the second aerosol generating device configured to operably engage the power source with an engagement portion between the one end of the control body and the first end of the cartridge body;

[0031] Embodiment 24 The method of any of the above or below embodiments, wherein the step of engaging the second aerosol generation device with the cartridge body includes inserting the second aerosol generation device into the second tubular member of the cartridge body between the first aerosol generation device and the second end of the second tubular member, the second end facing the first end and configured as a mouth-engagement end.

[0032] Embodiment 25 The method of any of the above or below embodiments, or a combination thereof, wherein inserting the second aerosol-generating device into the second tubular member further comprises inserting at least one aerosol-generating element into the second tubular member that at least partially forms the second aerosol-generating device, wherein the at least one aerosol-generating element is selected from the group consisting of granules, pellets, beads, small discrete units, carbon pieces, extruded carbon pieces, ceramic beads, marmerized tobacco pieces, extruded or compressed cylindrical or spherical elements, ground tobacco flakes, fillers, flavors, visible aerosol-forming material, binders, oval elements, irregularly shaped elements, shreds, flakes, tobacco-containing elements, visible aerosol-forming material-containing elements, adsorbent materials, absorbent materials, capsules, microcapsules, honeycomb monoliths, single porous structures, and combinations thereof.

[0033] Embodiment 26 The method of any of the above or below embodiments, or a combination thereof, further comprising inserting a first separation element within the second tubular member between the first aerosol generation device and the second aerosol generation device, wherein the first separation element is either thermally conductive and gas permeable.

[0034] Embodiment 27 The method of any of the above or below embodiments, or a combination thereof, further comprising inserting a second separation element within the second tubular member between the second aerosol generating device and the mouth engaging end, wherein the second separation element is one of thermally conductive and gas permeable.

[0035] Embodiment 28 The method of any of the above or below embodiments, or a combination thereof, wherein the second aerosol generation device comprises a cartridge having an elongated tubular body and opposing end members, each of the end members being one of thermally conductive and gas permeable, the elongated tubular body being further configured to receive at least one aerosol generation element and cooperate with the opposing end members to accommodate the at least one aerosol generation element therein, and wherein inserting the second aerosol generation device further comprises inserting the cartridge into the second tubular member of the cartridge body.

[0036] Embodiment 29 A method of forming an aerosol delivery system, comprising: engaging one end of a first elongated tubular member with a first end of a second tubular member configured as a control body portion and having a power source disposed therein; and engaging a second tubular member configured as a cartridge body portion and having a first aerosol generation device disposed therein, the first aerosol generation element being configured to operably engage the power source with an engagement portion between the one end of the control body portion and the first end of the cartridge body portion; and engaging the cartridge body portion with the second aerosol generation device such that the second end of the cartridge body portion faces the mouth engagement end of the aerosol delivery system and the second aerosol generation device is disposed between the first aerosol generation device and the mouth engagement end of the aerosol delivery system.

[0037] Embodiment 30 The method of any of the preceding or following embodiments, wherein the second aerosol generating device includes a plurality of aerosol generating elements in the form of beads or pellets held in place by a first air-permeable separation element disposed within the second tubular member between the first aerosol generating device and the second aerosol generating device, and a second separation element between the second aerosol generating device and the mouth-engaging end.

[0038] Embodiment 31 The method of any of the above or below embodiments, wherein the step of engaging the second aerosol generation device with the cartridge body portion includes removably engaging the second aerosol generation device with the cartridge body portion, the second aerosol generation device having a first end configured to removably engage with the cartridge body portion and a second end configured to provide a mouth-engagement end of the aerosol delivery system, and the second aerosol generation device having a plurality of bead-like or pellet-like aerosol generation elements held in place by a first air-permeable separation element between the first aerosol generation device and the second aerosol generation device, and a second separation element between the second aerosol generation device and the mouth-engagement end.

[0039] Embodiment 32 The method of any of the preceding or following embodiments, wherein the second aerosol-generating device comprises a plurality of aerosol-generating elements in the form of beads or pellets, each of which comprises at least one aerosol-forming material.

[0040] Embodiment 33 The method of any of the preceding or following embodiments, wherein the aerosol-generating element further comprises one or more of granular tobacco, tobacco extract, and nicotine, wherein the nicotine is in free base form, a salt form, a complex, or a solvate.

[0041] Embodiment 34 The method of any of the above or below embodiments, wherein the aerosol-generating element further comprises one or more fillers, binders, flavorings, and combinations thereof.

[0042] Embodiment 35 The method of any of the preceding or following embodiments, wherein the aerosol-generating element is smoked.

[0043] Embodiment 36 an aerosol delivery system comprising: a control body portion including a first elongated tubular member having opposing ends and a power source disposed therein; a cartridge body portion including a second tubular member having opposing first and second ends, the first end engaging one of the opposing ends of the control body portion; and a first aerosol generation device disposed in the second tubular member, the first end configured to operably engage the power source upon engagement between one of the opposing ends of the control body portion and the first end of the cartridge body portion, the second end of the cartridge body portion facing a mouth engagement end of the aerosol delivery system; and a second aerosol generation device disposed between the first aerosol generation device and the mouth engagement end of the aerosol delivery system and removably engaging with the cartridge body portion or housed in the second tubular member of the cartridge body portion, the second aerosol generation device further comprising a plurality of bead-shaped or pellet-shaped aerosol generating elements.

[0044] Embodiment 37 The aerosol delivery system of any of the preceding or following embodiments, or a combination thereof, wherein the second aerosol generating device comprises an external housing body and a plurality of stackable, gas-permeable containers within the external housing body, each container housing a plurality of aerosol generating elements.

[0045] Embodiment 38 The aerosol delivery system of any of the preceding or following embodiments, or a combination thereof, wherein the second aerosol generating device comprises an outer housing body and an inner compartment subdivided into a plurality of sub-compartments, each sub-compartment housing a plurality of aerosol generating elements.

[0046] Embodiment 39 The aerosol delivery system of any of the preceding or following embodiments, or combinations thereof, wherein the beads or pellets comprise a substrate material selected from the group consisting of glass beads, fibers, honeycomb structures, porous monoliths, and polymeric beads.

[0047] Embodiment 40 The aerosol delivery system of any of the preceding or following embodiments, or combinations thereof, wherein each bead or pellet is in the form of an extruded material comprising a particulate material selected from tobacco material and a filler, at least one aerosol-forming material, and at least one binder.

[0048] Embodiment 41 The aerosol delivery system of any of the preceding or following embodiments, or combinations thereof, wherein the aerosol-generating element further comprises one or more flavorants.

[0049] These and other features, aspects, and advantages of the present disclosure will become apparent from a reading of the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four, or more of the above-described aspects, as well as combinations of two, three, four, or more features or elements described in this disclosure, whether or not they are explicitly combined in the description of a particular embodiment herein. The present disclosure is intended to be read holistically, such that it should be considered that any separable features or elements of the disclosed invention are intended to be combinable in any of its various aspects and embodiments, unless the context clearly dictates otherwise.

[0050] Having thus generally described the present disclosure, reference is now made to the accompanying drawings, which are not necessarily drawn to scale. [Brief explanation of the drawings]

[0051] [Figure 1] 1 is a schematic diagram of an aerosol delivery device including a cartridge body shown in an exploded configuration and a control body shown in an assembled configuration, according to an exemplary embodiment of the present disclosure. [Figure 2] 2 is a schematic diagram of the control body of FIG. 1 shown in an exploded configuration, according to an exemplary embodiment of the present disclosure. [Figure 3] 2 is a schematic diagram of the cartridge body of FIG. 1 implementing an additional aerosol generating device including one or more aerosol generating elements, according to an exemplary embodiment of the present disclosure. [Figure 4] FIG. 4 is a schematic diagram of the additional aerosol generating device of FIG. 3 configured as a cartridge containing one or more aerosol generating elements, according to another embodiment of the present disclosure. [Figure 5] FIG. 10 is an exploded schematic view of an alternative carbon-based cartridge body according to an exemplary embodiment of the present disclosure. [Figure 6A] FIG. 6 is an assembled schematic diagram of the carbon-based cartridge body of FIG. 5 according to an exemplary embodiment of the present disclosure. [Figure 6B]FIG. 1 is an assembled schematic diagram of a carbon-based cartridge body implementing an additional aerosol generating device, including one or more aerosol generating elements, according to one embodiment of the present disclosure. [Figure 7] FIG. 1 is a cross-sectional view of a second aerosol generating device housed within the same outer body as a first aerosol generating device according to an exemplary embodiment of the present disclosure. [Figure 8] FIG. 1 is a cross-sectional view of a second aerosol generating device removably attached to an outer body housing a first aerosol generating device according to an exemplary embodiment of the present disclosure. [Figure 9] FIG. 10 is a cross-sectional view of a second aerosol generating device comprising multiple stackable components. [Figure 10] FIG. 1 is a top view of an aerosol generating device in the form of multiple wedges. DETAILED DESCRIPTION OF THE INVENTION

[0052] The present disclosure will now be described more fully hereinafter with reference to exemplary embodiments. These exemplary embodiments are described 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 disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly dictates otherwise.

[0053] As described below, aspects of the present disclosure relate to aerosol delivery systems. Aerosol delivery systems according to the present disclosure use electrical energy to heat materials (preferably by modest combustion of the materials) to form an inhalable substance, and the components of such systems are sufficiently compact in shape that they are most suitable for such systems to be considered handheld. That is, the use of preferred aerosol delivery system components does not result in the production of smoke, in the sense that the aerosol is primarily derived from by-products of tobacco combustion or pyrolysis, but rather results in the production of vapors (including vapors within the aerosol that may be considered visible / invisible aerosols that may be described as smoke-like) derived from the volatilization or evaporation of certain components incorporated therein. In preferred aspects, the components of the aerosol delivery system may be characterized as electronic cigarettes, which most preferably incorporate tobacco and / or tobacco-derived components and thus deliver tobacco-derived components in aerosol form.

[0054] The aerosol-generating strips of certain preferred aerosol delivery systems may provide many of the sensations of smoking a cigarette, cigar, or pipe (e.g., the inhalation and exhalation ritual, flavor or taste type, sensory impact, physical sensation, usage ritual, visual cues, such as those provided by a visible aerosol, etc.) provided by lighting and burning tobacco (and thus inhaling tobacco smoke), without substantially burning any of its components to any extent. For example, a user of an aerosol-generating strip of the present disclosure can hold and use the strip as a smoker would a traditional smoking article, drawing on one end of the strip to inhale the aerosol generated by the strip and taking puffs at selected time intervals.

[0055] The aerosol delivery systems of the present disclosure may also be characterized as suitable vapor-producing articles, aerosol-producing articles, or drug-delivery articles. Accordingly, such articles, systems, or devices may be adapted to provide one or more substances (e.g., flavors, active pharmaceutical ingredients, peptides, protein fragments, and / or protein films) in an inhalable form or state. For example, the inhalable substance may be substantially in vapor form (i.e., a substance that is 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 solid particulates or liquid droplets in a gas). For simplicity, as used herein, the term "aerosol" refers to vapor, gas, aerosol, and / or particulate form or type suitable for human inhalation, whether visible or invisible, and whether or not considered "smoke-like."

[0056] The aerosol delivery systems of the present disclosure most preferably comprise some combination of a power source (i.e., a power source), at least one control component (e.g., a means for activating, controlling, regulating, and / or terminating the supplied electrical power for heat generation, such as by controlling the flow of electrical current from a power-emitting device to other components of the aerosol generation device), a heating or heat-generating component (e.g., an electrical resistance heating element and related components commonly referred to as providing an "atomizer"), an aerosol precursor composition (e.g., a generally liquid component capable of generating an aerosol upon application of sufficient heat, such as components commonly referred to as "smoke juice," "e-liquid," or "e-juice"), and a mouth-end region, mouth-engagement end, or mouthpiece for enabling aspiration on the aerosol delivery system for aerosol inhalation (e.g., a defined airflow path through the aerosol generation device through which the generated aerosol can be drawn by inhalation).

[0057] More specific formats, configurations, and arrangements of components in the aerosol delivery systems of the present disclosure are provided below. Additionally, the selection and arrangement of various aerosol delivery system components can be understood by considering commercially available electronic aerosol delivery devices, such as the representative products referenced in the background section of this disclosure.

[0058] In some aspects, use of the aerosol delivery device of the present disclosure may involve many of the actions taken by an individual using a traditional smoking article. For example, a user of the aerosol delivery device of the present disclosure can hold the article like a traditional smoking article, draw on one end of the article to inhale the aerosol produced by the article, and take puffs at selected time intervals or for a selected period of time.

[0059] An example of such an aerosol delivery system is shown in FIG. 1. Specifically, FIG. 1 shows a partially exploded view of an aerosol delivery system 100 including a cartridge body 200 and a regulator 300 (alternatively referred to herein as a "cartridge body portion" and a "regulator portion," respectively). The cartridge body 200 and regulator 300 may be permanently or removably aligned or removably engaged in a operative relationship. Various mechanisms may be used to couple the cartridge body 200 to the regulator 300, providing a threaded engagement, a press-fit engagement, a snug fit, a magnetic engagement, or the like. When the cartridge body 200 and regulator 300 are in an assembled configuration, the aerosol delivery system 100 may, in some embodiments, be substantially rod-shaped, substantially tubular, or cylindrical. As used herein, "tubular" refers to a hollow, elongated body, but is not limited to a particular cross-sectional shape or a particular body exterior contour. Those skilled in the art will also understand that in some cases, although not described in detail herein, the cartridge body 200 and control body 300 forming the aerosol delivery system 100 may be configured in a single piece, non-detachable shape and may incorporate components, aspects and features related to and disclosed in the present disclosure.

[0060] In some examples, either or both of the cartridge body 200 and the control body 300 may be referred to as disposable (i.e., the single-piece, non-detachable type previously disclosed) or reusable. For example, the reusable control body 300 may use a replaceable or rechargeable battery and, therefore, may be combined with any type of charging technology, including connection to a typical AC outlet, a vehicle charger (i.e., cigarette lighter socket), and a computer, such as via a universal serial bus (USB). Generally, aerosol delivery systems of the type disclosed herein incorporate a battery or other power source to provide sufficient current to serve various functions in the article, such as powering a heater or heating element, powering a control system, and powering a display. The power source can take various forms. Preferably, the power source delivers sufficient power to rapidly heat the heating element and provide aerosol formation for the desired period of use and to operate the article. The power source is preferably sized to fit conveniently into the aerosol delivery device / system so that it is easy to operate, and further, a preferred power source is light enough so as not to detract from the desired smoking experience. Additionally, in some cases, cartridge body 200 may comprise a single-use cartridge (i.e., disposable), such as those disclosed in U.S. Patent Application Publication No. 2014 / 0060555 to Chang et al., which is incorporated herein by reference in its entirety.

[0061] 2 shows an exploded view of a control body 300 of another example aerosol delivery system 100. As shown, the control body 300 includes a coupler 302, an outer body 304, a sealing member 306, an adhesive member 308 (e.g., KAPTON® tape), a flow sensor 310 (e.g., a puff sensor or pressure switch), a control component 312, a spacer 314, a power source 316 (e.g., battery-rechargeable), a circuit board 318 with an indicator (e.g., a light-emitting diode (LED)), a connector circuit 320, and an end cap 322. Examples of power sources are described in U.S. Patent Application Publication No. 2010 / 0028766 to Pecherar et al., the disclosure of which is incorporated herein by reference in its entirety.

[0062] With respect to the flow sensor 310, representative current regulating and other current controlling components, including various microcontrollers, sensors, and switches for aerosol delivery devices / systems, are described in, for example, U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 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., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No. 8,205,622 to Pan, U.S. Patent Publication No. 2009 / 0230117 to Fernando et al., U.S. Pat. No. 2014 / 0060554 to Collett et al., U.S. Pat. No. 2014 / 0270727 to Ampolini et al., and U.S. Patent Application No. 14 / 209,191, filed March 13, 2014, which are incorporated herein by reference.

[0063] In some examples, the indicator 318 may include one or more light-emitting diodes. The indicator 318 communicates with the control component 312 via the connector circuit 320 and may illuminate while a user draws on the cartridge body 200 coupled with the coupler 302, for example, as sensed by the flow sensor 310. The end cap 322 may be adapted to visualize the illumination provided by the indicator 318. Thus, the indicator 318 may illuminate during use of the aerosol delivery system 100, simulating the lit end of a smoking article. However, in other examples, the indicator 318 may be provided with various numbers, may take on different shapes, or may be an aperture in the outer body (e.g., to emit a sound when such an indicator is present). Further exemplary types, configurations, and uses of indicators, such as components or light-emitting diode (LED) components that produce visual cues, are described in U.S. Patent Nos. 5,154,192 to Sprinkel et al., 8,499,766 to Newton, and 8,539,959 to Scatterday, and U.S. Patent Application No. 14 / 173,266, filed February 5, 2014, which are incorporated herein by reference.

[0064] Additionally, features, controls, and components that can be incorporated into the aerosol delivery devices and systems of the present disclosure are described in U.S. Patent No. 5,967,148 to Harris et al., U.S. Patent No. 5,934,289 to Watkins et al., U.S. Patent No. 5,954,979 to Counts et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,726,320 to Robinson et al., U.S. Patent No. 8,365,742 to Hon, U.S. Patent No. 8,689,804 to Fernando et al., U.S. Patent Application Publication No. 2013 / 0192623 to Tucker et al., U.S. Patent No. 2013 / 0298905 to Leven et al., U.S. Patent No. 2013 / 0180553 to Kim et al., U.S. Patent No. 2014 / 0000638 to Sebastian et al., U.S. Patent No. 2014 / 0000638 to Novak ... III et al., U.S. Patent Application Publication Nos. 2014 / 0161495 and 2014 / 0261408 to DePiano.

[0065] Returning to FIG. 1 , cartridge body 200 is illustrated in an exploded configuration. As shown, according to an exemplary embodiment of the present disclosure, cartridge body 200 may include a base shipping plug 202, a base 204, control component terminals 206, electronic control components 208, a flow tube 210, a sprayer 212, a reservoir board 214, an outer body 216, a label 218, a mouthpiece 220, and a mouthpiece shipping plug 222. Base 204 mates with a first end of outer body 216, and mouthpiece 220 mates with an opposing second end of outer body 216, within which the remaining components of cartridge body 200 may be housed. Base 204 may be configured to releasably engage with a coupler 302 of a control body 300. In some examples, the base 204 may include an anti-rotation feature that substantially prevents relative rotation between the cartridge body and the control body, as disclosed in U.S. Patent Application Publication No. 2014 / 0261495 to Novak III et al., which is incorporated herein by reference in its entirety. Various exemplary coupling mechanisms for upstream and downstream components of electronic cigarettes have been described in the patent literature and employed in the production of commercially available electronic cigarettes. For example, exemplary types of coupling mechanisms for electronic cigarettes are described in U.S. Patent Application Publication No. 2014 / 0261495 to Novak III et al. and U.S. Patent Application No. 14 / 170,838, filed February 3, 2014, by Bless et al., which are incorporated herein by reference.

[0066] Base shipping plug 202 may be configured to engage and protect base 204 prior to use of cartridge body 200. Similarly, mouthpiece shipping plug 222 may be configured to engage and protect mouthpiece 220 prior to use of cartridge body 200. Control component terminals 206, electronic control components 208, flow tube 210, nebulizer 212, and reservoir substrate 214 (which engages the aerosol precursor composition or aerosol precursor material) may be retained within outer body 216. Label 218 at least partially surrounds outer body 216 and may include information such as a product identification.

[0067] The arrangement of components within either or both of the controller and cartridge body of the aerosol delivery device and system may vary. In specific embodiments, the aerosol precursor composition may be located near one end of the overall article (e.g., in a cartridge body that may be replaceable and disposable in certain circumstances) and may be configured to be located relatively close to the user's mouth to maximize delivery of the aerosol to the user. However, other configurations are not excluded. Generally, the heating element is located sufficiently close to the aerosol precursor composition so that heat from the heating element can volatilize the aerosol precursor (and / or one or more flavorants, medications, etc. that may also be provided for delivery to the user) to form the aerosol for delivery to the user. When the heating element heats the aerosol precursor composition, an aerosol is formed, emanated, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the terms emanating, emanating, emanating (third person), or emanated are meant to be interchangeable, including forming or generating, forming or generating, and formed or generated. Specifically, the inhalable substance is emitted in the form of a vapor, an aerosol, or a mixture thereof. Furthermore, the selection of various aerosol delivery device components can be understood by considering commercially available electronic aerosol delivery devices, such as the exemplary products described above in this disclosure.

[0068] The atomizer (i.e., aerosol generating device) 212 may include a first heating terminal 234a and a second heating terminal 234b, a liquid transport element 238, and a heating element 240. In this regard, the reservoir and / or reservoir substrate 214 may be configured to hold an aerosol precursor composition. The aerosol precursor composition, also referred to as a vapor precursor composition, may include various components in different embodiments. By way of example, such components may include any of a polyhydric alcohol (e.g., glycerin, propylene glycol, or a mixture thereof), nicotine, tobacco, tobacco extract, water, flavorings, and combinations thereof.

[0069] The aerosol precursor or precursor composition may vary. Most preferably, the aerosol precursor composition is comprised of a combination or mixture of various components or constituents. The selection of specific aerosol precursor components and the relative amounts of these components used may be varied to control the overall chemical composition of the mainstream aerosol generated by the aerosol generating device. Of particular importance to the aerosol precursor composition is that it may generally be characterized as liquid in nature. For example, a typical aerosol precursor composition may be in the form of a solution, a viscous gel, a mixture of miscible components, or a liquid incorporating suspended or dispersed components. Typical aerosol precursor compositions are capable of vaporizing upon exposure to heat under conditions encountered during use of the aerosol generating device featured in the present disclosure, thus producing an inhalable vapor and aerosol.

[0070] In aerosol delivery systems characterized as electronic cigarettes, the aerosol precursor composition most preferably incorporates tobacco or tobacco-derived components. On the one hand, tobacco may be provided as tobacco parts or pieces, such as finely ground, crushed, or pulverized tobacco flakes. On the other hand, tobacco may be provided in the form of an extract, such as a spray-dried extract, that incorporates many of the water-soluble components of tobacco. Alternatively, the tobacco extract may be in the form of a relatively high nicotine-containing extract, which also incorporates smaller amounts of other tobacco-derived extracted components. On the other hand, tobacco-derived components may be provided in a relatively pure form, such as certain tobacco-derived flavorings. On the other hand, a tobacco-derived component that is highly refined or employed in an essentially pure form is nicotine (e.g., pharmaceutical-grade nicotine).

[0071] As mentioned above, highly purified tobacco-derived nicotine (e.g., pharmaceutical-grade nicotine with a purity of greater than 98% or greater than 99%) or derivatives thereof may be used in the present invention. Representative nicotine-containing extracts may be provided using the techniques described in U.S. Patent No. 5,159,942 to Brinkley et al., incorporated herein by reference. In some embodiments, the products of the present invention may contain nicotine in any form from any source, whether tobacco-derived or synthetic. The nicotine compound used in the products of the present invention may include nicotine in its free base form, salt form, complex, or solvate form. See, for example, the discussion of nicotine in the free base form in U.S. Patent Publication No. 2004 / 0191322 to Hansson, incorporated herein by reference. At least a portion of the nicotine compound may be employed in the form of a nicotine-resin complex in which nicotine is bound to an ion-exchange resin, such as nicotine polacrilex. See, for example, U.S. Patent No. 3,901,248 to Lichtneckert et al., incorporated herein by reference. At least a portion of the nicotine may be employed in salt form. Nicotine salts may be provided using the types of ingredients and techniques described in U.S. Patent No. 2,033,909 to Cox et al. and Perfetti, Beitrage Tabakforschung Int., 12, 43-54 (1983). Additionally, nicotine salts have been obtained from sources such as Pfaltz and Bauer, Inc. and K&K Laboratories, Division of ICN Biochemicals, Inc. Exemplary pharmaceutically acceptable salts of nicotine include salts of nicotine such as tartrates (e.g., nicotine tartrate and nicotine bitartrate), chloride compounds (e.g., nicotine hydrochloride and nicotine dihydrochloride), sulfates, perchlorates, ascorbates, fumarates, citrates, malates, lactates, aspartates, salicylates, tosylates, succinates, pyruvates, and the like, as well as nicotine salt hydrates (e.g., nicotine zinc chloride-hydrate).In some embodiments, at least a portion of the nicotine component is in a salt form with an organic acid moiety, including but not limited to levulinic acid, as discussed in U.S. Patent Publication No. 2011 / 0268809 by Brinkley et al., which is incorporated herein by reference.

[0072] The aerosol precursor composition may also incorporate so-called "aerosol-forming materials." In some instances, such materials are capable of generating a visible (or invisible) aerosol when vaporized upon exposure to heat under conditions encountered during normal use of the aerosol generating devices specific to the present disclosure. Such aerosol-forming materials include various polyols or polyhydric alcohols (e.g., glycerin, propylene glycol, and mixtures thereof). Embodiments of the present disclosure also incorporate aerosol precursor components characterized as water, saline, water vapor, or aqueous liquids. During conditions of normal use of some aerosol generating devices, water incorporated within these aerosol generating devices may evaporate to produce components of the generated aerosol. Thus, for purposes of the present disclosure, water present in the aerosol precursor composition may be considered an aerosol-forming material.

[0073] Any of a wide variety of flavors or materials may be employed that modify the sensory characteristics or properties of the inhaled mainstream aerosol produced by the aerosol delivery system of the present disclosure. For example, any such flavor may be used in the aerosol precursor composition or aerosol precursor material to modify the flavor, aroma, or sensory properties of the aerosol. Some flavors may be provided from sources other than tobacco. Exemplary flavors may be natural or artificial in nature and may be employed as concentrates or flavor packages.

[0074] Exemplary flavorings include vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, and flavorings and flavor packages of the type and characteristics traditionally used in flavoring tobacco, cigars, and pipe tobacco. Syrups, such as high fructose corn syrup, may also be employed. Certain flavors may be incorporated into the aerosol-forming materials prior to formation of the final aerosol precursor mixture (e.g., certain water-soluble flavors may be incorporated into water, menthol may be incorporated into propylene glycol, certain composite flavor packages may be incorporated into propylene glycol, etc.). However, in some aspects of the present disclosure, the aerosol precursor composition does not include any flavorings, flavor profiles, or additives.

[0075] The aerosol precursor composition may also include components that exhibit acidic or basic properties (e.g., organic acids, ammonium salts, or organic amines). For example, certain organic acids (e.g., levulinic acid, succinic acid, lactic acid, and pyruvic acid) may be included in aerosol precursor formulations incorporating nicotine, preferably in amounts that are equimolar with nicotine (based on total organic acid content). For example, the aerosol precursor may include about 0.1-0.5 moles of levulinic acid per mole of nicotine, about 0.1-0.5 moles of succinic acid per mole of nicotine, about 0.1-0.5 moles of lactic acid per mole of nicotine, about 0.1-0.5 moles of pyruvic acid per mole of nicotine, or various permutations and combinations thereof, until the total amount of organic acids present is equimolar to the total amount of nicotine present in the aerosol precursor composition. However, in some embodiments of the present disclosure, the aerosol precursor composition does not include any acidic (or basic) properties or additives.

[0076] As one non-limiting example, a typical aerosol precursor composition or aerosol precursor material may include glycerin, propylene glycol, water, saline, nicotine, and combinations or mixtures of any or all of these components. For example, in one example, a typical aerosol precursor composition may include (by weight) about 70%-100% glycerin, about 80%-90% glycerin, about 5%-25% water, often about 10%-20% water, and about 0.1%-5% nicotine, often about 2%-3% nicotine. As one specific non-limiting example, a typical aerosol precursor composition may include 84% glycerin, 14% water, and 2% nicotine. A typical aerosol precursor composition may also include propylene glycol, optional flavorings, or other additives in varying amounts by weight. In some examples, the aerosol precursor composition may include up to about 100% by weight of any of glycerin, water, and saline, as needed or desired.

[0077] Additionally, exemplary types of aerosol precursor components and aerosol precursor formulations are described and characterized in U.S. Patent No. 7,217,320 to Robinson et al., and U.S. Patent Publication Nos. 2013 / 0008457 to Zheng et al., 2013 / 0213417 to Chong et al., and 2014 / 0060554 to Collett et al., the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be employed include the aerosol precursors incorporated into RJ Reynolds Vapor Company's VUSE® products, Lorillard Technologies' BLU™ products, Mistic Ecigs' MISTIC MENTHOL products, and CN Creative Ltd.'s VYPE products. Also desirable are so-called "smoke juices" for e-cigarettes available from Johnson Creek Enterprise LLC.

[0078] The amount of aerosol precursor incorporated into the aerosol delivery system is such that the aerosol generating device provides acceptable sensory and desired performance characteristics. For example, it is highly preferred that a sufficient amount of aerosol-forming material (e.g., glycerin and / or propylene glycol) be employed to provide for the generation of mainstream aerosols (visible or invisible) that resemble in many respects the appearance of cigarette smoke. The amount of aerosol precursor composition in the aerosol generating device may depend on factors such as the number of desired doses per aerosol generating device. Typically, the amount of aerosol precursor composition incorporated into the aerosol delivery system, and specifically the amount of aerosol precursor composition incorporated into the aerosol generating device, is less than about 2 g, generally less than about 1.5 g, often less than about 1 g, and frequently less than 0.5 g.

[0079] The reservoir substrate 214 may comprise multiple layers of nonwoven fibrous fabric formed into a cylindrical shape that surrounds the interior of the outer body 216 of the cartridge body 200. Thus, for example, a liquid component can be sorptively retained by the reservoir substrate 214. The reservoir substrate 214 is fluidly connected to a liquid transport element 238. The liquid transport element 238 may be configured to transport the liquid (i.e., the aerosol precursor composition) from the reservoir substrate 214 to the heating element 240 via capillary action. Exemplary types of substrates, reservoirs, or other components for supporting the aerosol precursor composition are described in U.S. Pat. No. 8,528,569 to Newton, U.S. Patent Application Publication Nos. 2014 / 0261487 to Chapman et al. and 2015 / 0059789 to Davis et al., and U.S. Application No. 14 / 170,838, filed February 3, 2014, which are incorporated herein by reference. Additionally, various wicking materials and the configuration and operation of wicking materials in certain types of e-cigarettes are described in U.S. Patent Application Publication No. 2014 / 0209105 to Sears et al., which is incorporated herein by reference.

[0080] As shown, the liquid transport element 238 may be in direct contact with the heating element 240. Further, as shown in FIG. 1 , the heating element 240 may include a wire defining multiple coils wound around the liquid transport element 238. In some examples, the heating element 240 may be formed by winding a wire around the liquid transport element 238 as described in U.S. Patent Application Publication No. 2014 / 0157583 to Ward et al., which is incorporated herein by reference in its entirety. Furthermore, in some examples, the wire may define variable coil spacing as described in U.S. Patent Application Publication No. 2014 / 0270730 to DePiano et al., which is incorporated herein by reference in its entirety. Various materials configured to generate heat when an electric current is applied may be employed to form the heating element 240. Examples of materials from which the wire coil can be formed include Kanthal (FeCrAl), nichrome, molybdenum disilicide (MoSi), molybdenum silicide (MpoSi), molybdenum disilicide with aluminum addition (Mo(Si,Al)), graphite and graphite-based materials, and ceramics (e.g., positive or negative temperature coefficient ceramics).

[0081] However, various other methods may be employed to form the heating element 240, and various other aspects of the heating element may be employed in the atomizer 212. For example, a stamped heating element may be employed in the atomizer, as described in U.S. Patent Application Publication No. 2014 / 0270729 to DePiano et al., which is incorporated herein by reference in its entirety. Further exemplary heating elements and materials for use in nebulizers 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 to Deevi et al., U.S. Patent No. 5,228,460 to Sprinkel Jr. et al., U.S. Patent No. 5,322,075 to Deevi et al., U.S. Patent No. 5,353,813 to Deevi et al., U.S. Patent No. 5,498,850 to Das, U.S. Patent No. 5,659,656 to Das, U.S. Patent No. 5,498,855 to Deevi et al., U.S. Patent No. 5,530,225 to Hajaligol, U.S. Patent No. 5,665,262 to Hajaligol, U.S. Patent No. 5,573,368 to Das et al., and U.S. Patent No. 5,591,368 to Fleischhauer et al., the disclosures of which are incorporated herein by reference in their entireties. Additionally, chemical heating may be employed in other embodiments. Additionally, various heater components may be used in certain embodiments of the present aerosol delivery devices / systems. In various examples, one or more microheaters or similar solid-state heating elements may be used. Exemplary microheaters that may be utilized are further described herein. Additionally, microheaters and nebulizers incorporating microheaters suitable for use in the aerosol delivery devices / systems of the present disclosure are described in U.S. Patent Application Publication No. 2014 / 0060554 to Collett et al., which is incorporated herein by reference in its entirety.

[0082] When the cartridge body 200 is coupled to the controller 300, the first and second heating terminals 234a and 234b (e.g., positive and negative terminals) on opposing ends of the heating element 240 are configured to form an electrical connection (e.g., a detachable connection) with the controller 300. Furthermore, when the controller 300 is coupled to the cartridge body 200, the electronic control component 208 may form an electrical connection with the controller 300 via the control component terminals 206. Thus, the controller 300 may employ the electronic control component 208 to determine whether the cartridge body 200 is authentic and / or to perform other functions. Furthermore, various examples of electronic control components and functions performed thereby are described in U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., which is incorporated herein by reference in its entirety.

[0083] During use, a user may draw on the mouthpiece or mouth-engagement end 220 of the cartridge body 200 of the aerosol delivery system 100. This may draw air through an opening in the regulator 300 and / or cartridge body 200. For example, in one example, an opening may be defined between the coupler 302 and the outer body 304 of the regulator 300, as described in U.S. Patent Application Publication No. 2014 / 0261408 to DePiano et al., which is incorporated herein by reference in its entirety. However, in other embodiments, the air flow may be received through other portions of the aerosol delivery device / system 100. As described above, in some embodiments, the cartridge body 200 may include a flow tube 210. The flow tube 210 may be configured to direct the air flow received from the regulator 300 to the heating element 240 of the nebulizer 212.

[0084] A sensor of aerosol delivery device / system 100 (e.g., a puff sensor or flow sensor in controller 300) may sense inhalation. More generally, a sensor or detector may be implemented to control the supply of current to heating element 240 when aerosol generation is desired (e.g., relative to inhalation during use). Thus, for example, a technique or method is provided for turning off power to heating element 240 when aerosol generation is not desired during use, and for powering heating element 240 to activate or induce heat generation by heating element 240 during inhalation. Further exemplary types of sensing or detection mechanisms, structures, and configurations of aerosol delivery device / system 100, its components, and its general method of operation are described in U.S. Pat. No. 5,261,424 to Sprinkel, Jr., U.S. Pat. No. 5,373,148 to McCafferty et al., and PCT Publication No. WO 2010 / 003480 to Flick, which are incorporated herein by reference. Upon sensing a swallow, controller 300 may induce an electrical current to heating element 240 via a circuit including first heating terminal 234a and second heating terminal 234b. Heating element 240 may thus vaporize the aerosol precursor composition induced by liquid transport element 238 from reservoir substrate 214 to the aerosolization region. Mouthpiece 220 may thereby permit the passage of air and entrained vapor from cartridge body 200 to a consumer inhalation location on the cartridge body. Various other details regarding components that may be included in cartridge body 200 are provided, for example, in U.S. Patent Application Publication No. 2014 / 0261495 to Novak III et al., which is incorporated herein by reference in its entirety.

[0085] Various components of the aerosol delivery device / system may be selected from those described in the art and commercially available. See, for example, Sebastian et al., U.S. Patent Application Publication No. 2014 / 0000638, entitled "Reservoir and Heater System for Controllable Delivery of Multiple Aerosolizable Materials in an Electronic Smoking Article," which is incorporated herein by reference in its entirety. It should be further noted that the reservoir and heater system portion of the cartridge body 200 shown in FIG. 1 is optional. In this regard, by way of example, the cartridge body 200 may not necessarily include the flow tube 210, the control component terminal 206, and / or the electronic control component 208 in some instances.

[0086] One particular embodiment of the present disclosure is shown, for example, in FIG. 3. In such an example, the cartridge body 200 may further incorporate a second aerosol generating device 400 (the nebulizer 212 is considered the "first aerosol generating device") longitudinally disposed on the outer body 216 between the nebulizer 212 and the mouthpiece or mouth-engagement end 220 of the cartridge body 200. In some embodiments, the second aerosol generating device 400 is entirely porous or configured to allow air to pass therethrough. In some particular examples, the second aerosol generating device 400 may include one or more aerosol generating elements 425, which may be comprised of at least one or more pellets, beads, other suitable components, or a combination thereof. In some examples, at least one or more pellets, beads, other suitable components, or combinations thereof, forming the aerosol generating element 425 may optionally be coaxially surrounded by a generally cylindrical thermally conductive member (not shown) and / or surrounded or jacketed by insulation (e.g., a nonwoven mat or a layer of glass filaments or glass fibers) or other suitable material (not shown).

[0087] The overall configuration of the second aerosol generating device 400 in the cartridge body 200 of the aerosol delivery device / system 100 may be considered to be generally cylindrical in nature. Exemplary preferred beads or other materials may be formed from formulations incorporating tobacco (e.g., granulated tobacco), components of tobacco and / or tobacco-derived materials (e.g., tobacco extracts, such as water-soluble tobacco extracts or nicotine derived from tobacco, including pharmaceutical-grade nicotine). Most preferably, the beads incorporate flavors and visible or invisible aerosol-forming materials (e.g., glycerin or other materials that produce visible vapors resembling smoke). That is, the components of the beads are preferably configured to act as substrate components for volatile flavors, vapor-forming materials, water vapor or other liquids, and / or aerosol-forming materials that the beads will carry. In some embodiments, the aerosol-generating element 425 may comprise, comprise, or be configured as, for example, marmerized tobacco beads of varying shape and size, monoliths of bonded (e.g., sintered) beads, porous monoliths (spongy-like porous structures), unitary porous structures, honeycomb monoliths or other porous geometric frameworks, single-piece porous materials, beads of extracted tobacco, beads of porous materials retaining tobacco extract (e.g., calcium carbonate, ceramic, glass, etc.), reconstituted tobacco shreds, expanded tobacco shreds, extruded rods of various materials retaining tobacco flavor (including hollow cylinders and slotted rods), shavings, fibers, flavor-releasing particles, flavor-retaining (and releasing) polymers, granules, co-crystals, capsules, powders, and / or microcapsules of various materials retaining tobacco flavor or other substances, whether in solid, liquid, gelatinous, colloidal, gaseous, or other form, and regardless of the treatment or combination of the following.

[0088] In some embodiments, the aerosol generating element 425 may be at least partially in the form of a coating or film on the wall or lining of the housing body that surrounds the aerosol generating element. For example, a film comprising microencapsulated flavorings may be coated on the wall or lining of the housing body.

[0089] Generally, as used herein, the terms "pellets" and "beads" are meant to include beads, pellets, or small, discrete units or pieces that may include, for example, (in addition to those disclosed herein) carbon flakes, extruded carbon flakes cut into pellets, ceramic beads, marmerized tobacco flakes, polymeric beads, glass beads, etc., or combinations thereof. For example, the granules, pellets, or beads may be generally cylindrical, extruded, or compressed granules, pellets, or beads composed of a wet mixture or slurry of ground tobacco flakes, a filler (e.g., granular calcium carbonate), flavors, visible aerosol-forming material, and a binder (e.g., carboxymethyl cellulose), which are formed, cut, or rolled to a desired size and shape, and then dried to retain the desired configuration. However, such "pellets" or "beads" may include any suitable component or combination of components that meets the preferred embodiments disclosed herein. For example, some or all of the beads or pellets may comprise heat-sensitive spherical capsules that, when contained in an aerosol-generating element and exposed to heat, rupture or decompose to release glycerin, propylene glycol, water, saline, tobacco flavoring, and / or nicotine, or other substances or additives. The beads may also comprise ceramic, absorbent clay, silica, or absorbent carbon to retain or release the aerosol former. Furthermore, in some embodiments, the beads / pellets may comprise a thermally conductive material, such as, for example, thermally conductive graphite, thermally conductive ceramic, metal, flake-cast tobacco, metal or other suitable material impregnated with a suitable aerosol-generating substance, such as glycerin and flavoring, or a suitable cast sheet material appropriately formed into the desired bead / pellet.

[0090] In one particular example, the beads / pellets (particles) may be composed of about 15% to 60% by weight finely ground tobacco particles (e.g., Oriental blend, burley and flue-cured tobacco, essentially all Oriental tobacco, essentially all burley tobacco, or essentially all flue-cured tobacco), about 15% to 60% by weight finely ground calcium carbonate particles (or finely ground clay or ceramic particles), about 10% to about 50% by weight glycerol (and optional minor amounts of flavoring), about 0.25% to about 15% by weight binder (preferably carboxymethylcellulose, guar gum, potassium or ammonium alginate), and about 15% to 50% by weight water. In another example, the beads / pellets (particles) may be composed of about 30% by weight finely ground tobacco particles (e.g., Oriental blend, burley and flue-cured tobacco, essentially all Oriental tobacco, essentially all burley tobacco, or essentially all flue-cured tobacco), about 30% by weight finely ground calcium carbonate particles (or finely ground clay or ceramic particles), about 15% by weight glycerol (and optional minor amounts of flavoring), about 1% by weight binder (preferably carboxymethylcellulose, guar gum, potassium, or ammonium alginate), and about 25% by weight water. In such an example, the particles may be compressed to retain the glycerol, and the compression may form a porous matrix that facilitates movement of the aerosol-generating elements and promotes efficient aerosol formation. The manner in which the aerosol-forming material contacts the substrate may vary. The aerosol-forming material may be added to a molding compound, incorporated into processing materials during their manufacture, or may be inherent in the materials. An aerosol-forming material, such as glycerin, may be dissolved or dissipated in an aqueous liquid, other suitable solvent, or liquid carrier, and sprayed onto a substrate material. See, e.g., U.S. Patent Application Publication No. 2005 / 0066986 to Nestor et al. and U.S. Patent Application Publication No. 2012 / 0067360 to Conner et al., both of which are incorporated herein by reference.Calcium carbonate or other inorganic fillers may help create porosity in the particles and, in some instances, may function to absorb heat, which can limit or prevent burnout of the aerosol-generating elements and promote and encourage aerosol formation. See also, for example, these types of materials described in U.S. Patent No. 5,105,831 to Banerjee et al. and U.S. Patent Application Publication No. 2004 / 0173229 to Crooks et al., U.S. Patent Application No. 2011 / 0271971 to Conner et al., and U.S. Patent Application Publication No. 2012 / 0042885 to Stone et al., which are incorporated herein by reference.

[0091] In some embodiments, the beads / pellets are in the form of small pieces of extruded material comprising particulate material that serves as a substrate for flavoring agents and / or aerosol-forming materials, such as tobacco (e.g., ground tobacco material) or filler material (e.g., rice flour or other grain-based material and / or calcium carbonate), one or more binders (e.g., carboxymethylcellulose), one or more flavoring agents (e.g., menthol), and one or more aerosol-forming materials (e.g., glycerin). Optionally, the beads / pellets may include one or more organic acids (e.g., levulinic acid or lactic acid) and / or one or more sweeteners (sugar or sugar substitutes). The above-mentioned materials may be mixed together, extruded, and broken into pieces of a desired size. Optionally, the mixed materials may be marmerized.

[0092] In one embodiment, the aerosol-generating elements 425, such as beads or pellets, may be smoked to impart a smoky flavor or aroma. For example, the beads or pellets may be prepared and then exposed to smoke from a combustible material, such as wood (e.g., hickory, maple, oak, apricot, cherry, or mesquite). The beads or pellets may be smoked for a time sufficient to impart the desired smoky flavor or aroma, an exemplary time being between 5 and 45 minutes. The manner in which the beads or pellets are exposed to the smoke can vary, and one example involves heating wood shavings in a container until they smoke (e.g., heating the wood shavings to about 350-400°F), and then placing the beads or pellets in a confined environment to be treated with the smoke generated by the wood shavings.

[0093] The components of the aerosol precursor composition of the first aerosol generating device and the aerosol precursor composition of the second aerosol generating device are advantageously selected to complement each other to produce a desired sensory experience. For example, in some embodiments, the nicotine content of the aerosol precursor composition and the aerosol generating element is selected so that the aerosol precursor composition and the aerosol generating element can retain nicotine or nicotine components or can be considered substantially or completely free of nicotine or nicotine components. In other words, all of the nicotine content may be in the aerosol generating element, all of the nicotine content may be in the aerosol precursor composition, or both components may contain nicotine in some form.

[0094] In some embodiments, when the aerosol generating element 425 includes, for example, beads, cast pellets, or extrudates of various types of materials described above (i.e., graphite beads containing tobacco extract and glycerin), the beads / pellets may be rolled, for example, between adjacent roller elements, while "wet" or before drying to flatten the shape of the respective beads / pellets. In some examples, the various types of materials described above may be extruded in the form of fibrous strands, which may be collected to form cylindrical rods or other suitable shapes of material for use in the second aerosol generating device 400. Once dried, the flattened beads / pellets may be cut or otherwise processed to form, for example, strands, flakes, or other filler configurations, including flat portions that are flat, prevent rotation, or inhibit rotation. Any random configuration resulting from the cutting process may suffice. In such an example, flattened and cut beads / pellets may be included in the aerosol generating element 425, and their irregular or random configuration may, for example, facilitate multiple intermediate spaces through the aerosol generating element 425, which may facilitate heat transfer with the individual substances in the aerosol generating element 425. That is, heating of the air in the intermediate spaces within the second aerosol generating device 400 exposes more of the aerosol generating element 425 to heat from the heating element 240, resulting in enhanced or improved heating of the aerosol generating element 425. In other examples, the heat generated by the heating element 240 / atomizer 212 and the first aerosol (i.e., the combination) is directed through a porous matrix formed by the aerosol generating element 425, through which the heated vapor passes, heating the constituent aerosol generating element 425, for example, to facilitate leaching (i.e., liquid, fluid, or particle extraction, steam distillation, etc.) of an enhancing substance (i.e., a flavorant or other additive) from the aerosol generating element into the first aerosol, or to facilitate an enhancing substance entrained with, imparted to, reacting with, or interacting with the first aerosol.The interaction between the enhancing substance and the first aerosol may, for example, alter or modify the first aerosol, mix the enhancing substance with the first aerosol, form an enhanced aerosol or aerosol mixture, or facilitate a reaction that produces a different aerosol. In such instances, the increased interspace within the aerosol generating element 425 may facilitate this interaction process via the second aerosol generating device 400.

[0095] In some embodiments, the beads / pellets may result from tobacco material cast onto a flake / laminate paper. More specifically, the tobacco material may comprise, for example, a slurry containing reconstituted tobacco, glycerin, and a binder material. Such tobacco materials are disclosed, for example, in U.S. Patent No. 5,101,839 to Jakob et al. and U.S. Patent Application No. 2010 / 0186757 to Crooks et al., both of which are incorporated herein by reference. In addition, the slurry may incorporate particulate inorganic materials (i.e., calcium carbonate). For example, as disclosed in U.S. Patent No. 8,678,013 to Crooks et al. and U.S. Patent No. 7,647,932 to Cantrell et al., both of which are incorporated herein by reference, the slurry is cast onto the paper elements of a flake laminate paper, and the assembled cast sheet product is dried, for example, by applying heat (i.e., heated air, microwave drying, etc.). The paper element may have, for example, a specific porosity and texture to promote intimate contact and interaction with the slurry, e.g., upon direct contact between the slurry and the flake. However, exemplary embodiments herein do not preclude casting tobacco material onto a metal foil or other suitable thin-film heat conductor. Once such a laminate is cast, the dried cast sheet (i.e., foil / paper / tobacco material) may be cut, shredded, or separated into multiple cast sheet components, each preferably including a portion of the tobacco material (i.e., substrate) that intimately interacts with a portion of the paper element, and a portion of the paper element that intimately contacts a portion of the foil element of the foil laminate paper. Multiple cast sheet components may be included in the aerosol generating element 425 that forms the second aerosol generating device 400.

[0096] In some circumstances, those skilled in the art will appreciate that cast sheet elements included in the aerosol-generating element 425 may cooperate to facilitate improved heat transfer to the tobacco material forming part of those cast sheet elements or to adjacent elements. More specifically, in some instances, heat transfer from the heating element 240 to the tobacco material included in the aerosol-generating element 425 may be limited beyond any direct interface therebetween, and thermally conductive pathways provide additional mechanisms for conducting heat from the heating element 240 to heat the aerosol-generating element 425 and any external elements included in the aerosol-generating element that come into contact with it. In embodiments including cast sheet elements included in the aerosol-generating element 425, the thermally conductive portions of the thin flake elements associated with the cast sheet elements may, for example, form multiple additional thermally conductive pathways. That is, the cast sheet element used as all or part of the aerosol-generating element 425 may provide additional thermally conductive elements dispersed throughout the aerosol-generating element 425 in the second aerosol-generating device 400, thereby enhancing or improving heat transfer to and between the aerosol-generating elements. To achieve such an embodiment, it may be further advantageous to cut or process the substrate material to be mounted onto the cast tobacco sheet substrate material that forms the substrate incorporated into cigarettes of the type sold by R.J. Reynolds Tobacco Company under the trade name "Eclipse," as disclosed, for example, in U.S. Patent No. 5,469,871 to Barnes et al.

[0097] The pellets or other elements may have a smooth, regular external shape (e.g., spherical, cylindrical, oval, etc.) and / or an irregular external shape (e.g., cut pieces, flakes, etc.). The aerosol generating element 425 may discretely or sequentially increase the generally cylindrical shape within the second aerosol generating device 400, and in some instances may collect approximately 800-1200 generally spherical beads, each having an average or nominal diameter of approximately 0.05 mm-4 mm (e.g., in one example, about 1 cubic millimeter), with the beads / pellets cumulatively weighing approximately 450 mg-750 mg (e.g., in one example, + / - 25% of 600 mg).

[0098] In one method of preparation, substantially spherical beads or pellets of the aerosol-generating elements are formed by first blending the desired ingredients, followed by extrusion of the ingredients to form an extrudate. The extrudate is then processed in a spheronizer (such as those available from Caleva Process Solutions Ltd or LCI Corporation) to produce spheres of various sizes that can be processed through a series of screens to provide the desired size range, such as those mentioned above.

[0099] The aerosol-generating elements may be selected to be of relatively uniform average diameter, or a range of sizes of aerosol-generating elements may be included in the second aerosol-generating device 400. When different size ranges are used in the same device, the various sized elements may be arranged in gradients or layers within the second aerosol-generating device 400, or the various sized elements may be randomly mixed within the aerosol-generating device 400. Without being bound to any particular theory of operation, the use of different sized aerosol-generating elements in the same aerosol-generating device 400 may advantageously vary the pressure drop within the device and / or provide advantageous sensory characteristics due to the different evaporation rates provided by the different sized elements.

[0100] Preferably, enough beads are inserted into the second aerosol generating device 400 to provide at least about 95% of the maximum fill volume with beads and / or other suitable elements. Advantageously, there are no large cavities within the aerosol generating device 400 that would allow air to flow through the aerosol generating device to substantially avoid interaction with the aerosol generating element 425.

[0101] In some examples, multiple shapes of aerosol generating elements 425 may be selected (e.g., aerosol generating elements having different components), and each selected shape of aerosol generating element may be subsequently placed in the aerosol generating device 400. In other examples, selected shapes of aerosol generating elements may be combined to generate a mixture of aerosol generating elements before being placed in a second aerosol generating device 400, and the mixture may then be placed in the second aerosol generating device 400.

[0102] The nebulizer or first aerosol generation device 212 and the second aerosol generation device 400 may be physically separated from one another and / or comprise discrete units or sections within the cartridge body 200. In some examples, as shown, the sections may be positioned / arranged such that the downstream end of the nebulizer or first aerosol generation device 212 (towards the mouthpiece or mouth-engagement end 220 of the cartridge body 200) is adjacent to the upstream end of the second aerosol generation device 400 (i.e., the backside of the aerosol generating element 425). That is, the nebulizer or first aerosol generation device 212 and the second aerosol-generation section 400 may be axially aligned in a continuous end-to-end relationship, in some examples, next to one another. For example, in some instances, it may be desirable for the aerosol-generating element 425 of the second aerosol-generating device 400 to be physically in contact with the heating element 240 at the downstream end of the nebulizer or first aerosol-generating device 212, while being physically discrete and positioned downstream from the nebulizer or first aerosol-generating device 212. Alternatively, the respective ends of these sections 212, 400 or their components 240, 425 may be slightly spaced apart from one another so that they are not in physical contact with one another (i.e., to prevent burnout). Those skilled in the art will understand that in some embodiments, the second aerosol-generating device 400 includes one or more sections or portions of the aerosol-generating element 425.

[0103] In some cases, an additional section, spacer element, or separator element (referred to herein as a “first separator element”), acting as a spacer or screen (see, for example, element 450 in FIG. 3 ), may be disposed generally perpendicular to the longitudinal axis of the cartridge body 200, and the first separator element 450 may physically separate these two components 212, 400 while, in some cases, maintaining a thermally conductive relationship therebetween. The first separator element 450 may not be thermally conductive in some cases and may not be electrically conductive in other cases. That is, the first separator element 450 may be thermally conductive and / or configured to conduct heat from the heating element 240 of the nebulizer / first aerosol-generating element 212 to the second aerosol-generating device 400, but this is not necessarily the case; the aerosol-generating element 425 may be thermally responsive and / or form a second aerosol associated with the first aerosol. Furthermore, in some examples, the first separation element 450 may be gas permeable or configured to allow airflow therethrough, such that the first aerosol generated by the nebulizer / first aerosol-generation device 400 can pass downstream through the first separation element 450. The first separation element 450 may also be configured / arranged to retain the aerosol-generation element 425 in the second aerosol-generation device 400 and separate it from the nebulizer / first aerosol-generation device 212. In further examples, the first separation element 450 may be configured as a spacer (i.e., extending longitudinally along the cartridge body 200 to define a thickness) that separates the aerosol-generation element 425 from the heating element 240 of the nebulizer / first aerosol-generation device 212, for example, to prevent the aerosol-generation element (i.e., bead) 425 from being burned or combusted by heat from the heating element 240. Also, in some examples, the first isolation element 450 may be configured as an insulator (i.e., not conductive) to prevent shorting of the heating element 240 in the event of contact between the first isolation element 450 and the heating element 240.

[0104] Typically, the first separation element 450 is generally cylindrical or disk-shaped, has a monolithic structure, and is air-permeable to allow the passage of aspirated air therethrough. The first separation element 450 may be essentially thermally conductive so that heat generated by the heating element 240 can be readily transferred to the second aerosol-generating device 400. The length (thickness) of the first separation element 450 is variable and typically extends from less than about 1 mm to about 10 mm. In some cases, the relative longitudinal positioning of the first separation element 450 within the outer body 216 separates the interface between the aerosol-generating element 425 and the first separation element 450 from the heating element 240 by between about 1 mm and about 20 mm (i.e., 7 mm in one example). Typically, the first separation element 450 is made of a heat-resistant material such as a porous ceramic, a porous graphite material, a metal (i.e., stainless steel, brass, copper, etc.), a mesh or screen, or a high-temperature resistant plastic. In some examples, the first separation element 450 may include longitudinally extending air channels formed, for example, during design / manufacturing, drilled, molded, extruded, printed (i.e., 3D printed elements using a 3D printer), or formed in a spacer element during manufacturing. If desired, the first separation element 450 may incorporate a catalytic material, such as a material incorporating cerium or copper ions or oxides and / or salts of cerium and copper ions. See, for example, U.S. Patent Nos. 8,469,035 and 8,617,263 to Benerjee et al., and U.S. Patent Application Publication No. 2007 / 0215168 to Benerjee et al., which are incorporated herein by reference.

[0105] In an example where the aerosol generating element 425 may be surrounded by an insulating layer, a layer of thermally conductive material (e.g., a layer or strip of metal foil) may be provided therebetween (not shown). That is, a typical aerosol generating element 425 includes a plurality of pellets and / or other suitable components that may be surrounded along its length by a layer of metal foil strips. A typical metal foil is, for example, aluminum foil approximately 0.01 mm to 0.05 mm thick. The metal foil preferably extends along the entire length of the outer coaxial surface of the aerosol generating element 425, and may preferably extend beyond (i.e., at least partially overlap) the first separation element 450. Thermally conductive material may be provided by means other than using metal foil. For example, the layer of metal foil may be replaced by a metal mesh or metal screen. Alternatively, the metal foil may be replaced by a thermally conductive fabric, such as a layer or sheet of graphite fiber or thermally conductive ceramic fiber. Alternatively, the thermally conductive material may be provided by the application of a thermally conductive ink, such as a coating of ink or paint incorporating metal particles, graphite fibers, thermally conductive ceramic materials, or the like.

[0106] 7 shows a further example embodiment of a second aerosol generation device 400 disposed within the outer body or tubular member 216 (downstream of the first aerosol generation device 212, not shown). As shown, the aerosol generation element 425 is disposed between separation elements 450 and 475, which serve to hold the aerosol generation element 425 in place and allow airflow therethrough. As noted above, the separation elements 450 and 475 may be perforated elements (e.g., mesh screens or perforated metal plates) with a hole size selected to retain the aerosol generation element 425 within the second aerosol generation device 400.

[0107] As shown, the second aerosol generating device 400 may further include another aerosol generating element housing 460, e.g., in the form of a cylindrical housing with an open end facing the mouthpiece 220. The mouthpiece 220 may engage with the open end of the cylindrical housing and be secured thereto by a press-fit or other known means, as shown. The housing 460 may include an end 470 facing the mouthpiece 220, which may be perforated to allow airflow therethrough, as shown. The housing 460 may be constructed of any suitable material, including metal (e.g., stainless steel) or plastic. Separation elements 450 and 475 may be press-fit or otherwise engaged with the housing 460, and the separation element 475 adjacent the mouthpiece 220 may be secured to the mouthpiece, if desired. In some embodiments, the separation elements 450 and 475 are incorporated into the housing 460 during the molding process that forms the housing. The design of Figure 7 is particularly suitable for embodiments of the present invention in which the second aerosol generating device 400 is permanently fixed to the cartridge body 200 rather than being separate and detachable or disposable from the rest of the cartridge body 200.

[0108] Alternatively, in embodiments in which the second aerosol generating device 400 is detachable from the cartridge body 200 as a separate unit, the design of FIG. 8 is advantageous. As shown, in the embodiment of FIG. 8, the second aerosol generating device 400 is formed as a separate unit with a separate housing body 520 and attached to the first connector 540 (e.g., via crimping or other means). The housing 520 and first connector 540 together form a cavity for the aerosol generating element 425. As in the embodiment of FIG. 7, the aerosol generating element 425 is disposed between the separation elements 450 and 475, which serve to hold the aerosol generating element 425 in place and allow airflow therethrough. As in the embodiment of FIG. 7, the separation elements 450 and 475 may be press-fit engaged or may engage with surrounding portions of the first connector 540 or housing body 520, respectively, and be incorporated into these surrounding portions during molding. The downstream separation element 475 is also optionally secured to the mouthpiece 220 .

[0109] The first connector 540 of the second aerosol generation device 400 is adapted to engage with a second connector 560 secured (e.g., via a press-fit engagement or other means) to the outer body or tubular member 216 housing the first aerosol generation device 212 (not shown). The second connector 560 has an end facing the first connector 540 that allows a user to removably secure the second aerosol generation device 400 to the cartridge body 200 via a threaded engagement or other coupling means. As shown, the second connector 560 is porous, allowing airflow from the first aerosol generation device 212 to enter the second aerosol generation device 400. The second aerosol generation device 400 of this embodiment cooperatively engages with the mouthpiece 220 in a manner similar to that shown in FIG. 7.

[0110] In some embodiments, another spacer element, or other separation element (herein referred to as a "second separation element"), acting as a spacer or screen (see, e.g., component 475 in FIG. 3 ), may be disposed generally perpendicular to the longitudinal axis of the cartridge body 200, and the second separation element 475 may physically separate the second aerosol generation device 400 from the mouthpiece or mouth-engagement end 220 of the cartridge body 200. That is, the second separation element 475 may, but is not necessarily, thermally conductive and / or configured to conduct heat from the second aerosol generation device 400 through the mouthpiece or mouth-engagement end 220 of the cartridge body 200. However, the second separation element 475 may be configured to be gas permeable or to allow airflow therethrough, such that the first aerosol generated by the nebulizer / first aerosol-generating device 212 and / or the second aerosol generated by the second aerosol-generating device 400 can pass downstream through the second separation element 475 and through the mouthpiece or mouth-engagement end 220 of the cartridge body 200. Thus, the second separation element 475 may also be configured and / or arranged to maintain the aerosol-generating elements 425 within the second aerosol-generating device 400 without losing any of the aerosol-generating elements through the mouthpiece or mouth-engagement end 220 of the cartridge body 200.

[0111] In some embodiments, instead of the discrete first and second separation elements 450 and 475 implemented in addition to the aerosol generation element 425, the second aerosol generation device 400 may comprise a cartridge 500 (see, e.g., FIG. 4 ) having an elongated tubular body 525 and opposing end members 550, 575, each of which may be thermally conductive and air permeable in a manner similar to the first and second separation elements 450, 475. Thus, the elongated tubular body 525 may be further configured to receive the aerosol generation element 425 and cooperate with the opposing end members 550, 575 to retain the aerosol generation element 425 therein. Thus, the assembled cartridge 500 may be configured to be received as a unit (forming the second aerosol generation device 400) by the outer body, i.e., tubular member 216, of the cartridge body 200.

[0112] FIG. 9 illustrates an embodiment of the present invention in which a housing body 520 houses multiple stackable containers 580a, 580b, and 580c, each housing an aerosol generating element 425. Each container, e.g., 580a, may contain a different aerosol generating element 425 to provide a different sensory experience. Thus, to vary the sensory experience of the aerosol delivery system 100, a user can stack multiple containers of different types in any desired order. Each individual container 580a, 580b, and 580c may have a similar structure, such as the general structure shown in FIG. 4, in which the aerosol generating element 425 is housed in a container having porous walls that allow gas flow therethrough. The number of stackable containers used is variable and is not limited to the three-container embodiment shown. An exemplary range for the total number of stackable containers is two to about eight (e.g., two, three, four, five, six, seven, or eight containers arranged in a stacked configuration).

[0113] FIG. 10 illustrates an embodiment in which a stackable container 580a, such as that illustrated in FIG. 9, has an interior wall dividing the interior compartment into multiple wedge-shaped compartments so that different aerosol generating elements 425 (e.g., 425a, 425b, 425c, and 425d) can be placed in separate compartments within the same container. The cross-sectional shape of each subdivided compartment need not be wedge-shaped. Additional non-limiting examples of compartment shapes include concentric circular, triangular, or rectangular compartments. The number and size of the subdivided compartments are variable and are not limited to the four-compartment embodiment shown. Exemplary ranges for the total number of compartments are from two to about six (e.g., two, three, four, five, or six compartments). The use of interior walls to divide a compartment into multiple compartments housing aerosol generating elements 425 is not limited to the stackable container embodiment of FIG. 9. For example, the single compartment depicted in FIG. 8 may also be subdivided in this manner.

[0114] During use, the mouthpiece or mouth-engaging end 220 of the cartridge body 200 of the aerosol delivery system 100 is inserted into the user's mouth. The nebulizer / first aerosol generation device 212 is activated, for example, by the user drawing (e.g., sucking) on ​​the mouthpiece or mouth-engaging end 220 of the cartridge body 200. The heating element 240 and the liquid transport element 238 are configured to be in a heat exchange relationship. That is, the heat generated by the heating element 240 acts to heat the aerosol precursor composition transported by the liquid transport element 238 to generate the first aerosol. The heat and first aerosol generated by the heating element 240 engage the second aerosol generation device 400 and are drawn through the second aerosol generation device 400 (i.e., via the aerosol generation element 425) toward an inhalation orifice defined by the mouthpiece or mouth-engaging end 220. In some examples, heat from the heating element 240 may interact with the aerosol generating element 425 to generate a second aerosol. The second aerosol may interact with or mix with the first aerosol to form a third aerosol, which is the aerosol delivered to the user through the mouthpiece 220 in response to inhalation applied by the user. In some examples, the heat and / or interaction between the first aerosol and the aerosol generating element 425 may result in an enhancing substance being added to the first aerosol to generate an enhanced aerosol. For example, a drug adsorbed to the aerosol generating element 425 may react with the first aerosol and / or heat, or may be desorbed from the aerosol generating element 425 by the first aerosol and / or heat and combine with the first aerosol to form the enhanced aerosol. In yet other examples, the aerosol generating element 425 may be configured such that interaction with the first aerosol draws heat away from the first aerosol (i.e., cooling the first aerosol). When properly implemented by a user, at least a first aerosol, generated by the nebulizer 212 and influenced by the second aerosol generating device 400, is generated and inhaled into the user's mouth.

[0115] The components within the second aerosol generating device 400 and / or the aerosol generating element 425 are variable. Generally, the second aerosol generating device 400 and / or the aerosol generating element 425 may incorporate components therein that evaporate, aerosolize, or are entrained in the air drawn through the aerosol delivery system 100 during use. Most preferably, these components, by themselves or in conjunction with the first aerosol generated by the first aerosol generating device 212, provide sensory and organoleptic effects such as aroma, flavor, mouthfeel, and visible aerosol sensation. Examples of components of the first and / or second aerosol generating devices 212, 400 drawn into the user's mouth during inhalation include water (e.g., as water vapor), visible or invisible aerosol-forming materials (e.g., glycerin), various volatile flavors (e.g., vanillin and menthol), volatile components of tobacco (e.g., nicotine), and the like.

[0116] Preferred aerosol-forming materials generate aerosols (whether visible or invisible) by applying sufficient heat thereto or through the action of aerosol-forming conditions using components of the aerosol delivery system. Preferred aerosol-forming materials generate visible aerosols, which may be considered "smoke-like." Preferred aerosol-forming materials are cost-effective compared to the chemical characteristics of smoke produced by burning tobacco. Preferred visible aerosol-forming materials are polyols, and exemplary preferred aerosol-forming materials include glycerin, propylene glycol, and mixtures thereof. If desired, the aerosol-forming material may be combined with other liquid materials, such as water. For example, the aerosol-forming material formulation may incorporate a mixture of glycerin and water or a mixture of propylene glycol and water. See, for example, the various aerosol-forming materials referenced in U.S. Patent No. 8,678,013 to Crooks et al., incorporated herein by reference.

[0117] The aerosol-forming material is held or supported by a substrate material to retain the aerosol material within a desired region of the smoking article. Exemplary substrate materials and formulations incorporating the aerosol-forming material are described in U.S. Patent No. 4,793,365 to Sensabaugh et al., U.S. Patent No. 4,893,639 to White, U.S. Patent No. 5,099,861 to Clearman et al., U.S. Patent No. 5,101,839 to Jakob et al., U.S. Patent No. 5,105,836 to Gentry et al., U.S. Patent No. 5,159,942 to Brinkley et al., U.S. Patent No. 5,203,335 to Clearman et al., U.S. Patent No. 5,271,419 to Arzonico et al., U.S. Patent No. 5,327,917 to Lekwauwa et al., U.S. Patent No. 5,327,917 to Casey et al., and ... Clearman et al., and U.S. Patent No. 5,203,335 to Clearman et al., U.S. Patent No. 5,271,419 to Arzonico et al., U.S. Patent No. 5,32 and U.S. Patent Application Publication No. 2005 / 0066986 to Nestor et al., which are incorporated herein by reference. See also, Chemical and Biological Studies on New Cigarette Prototype that Heat Instead of Burn Tobacco, RJ Reynolds Tabacco Company Monograph (1988). Exemplary substrate materials have been incorporated into cigarette types marketed under the trade names "Premier" and "Eclipse" under the RJ Reynolds Tabacco Company.

[0118] 1 may be used in much the same manner as commercially available e-cigarettes. As a result, when smoked, preferred aerosol delivery systems 100 of the type disclosed herein can produce a visible mainstream aerosol that results primarily from the volatilized components of the first and second aerosol-generating devices 212, 400, which in many ways resembles mainstream tobacco smoke from a traditional type of cigarette that burns tobacco cut filler.

[0119] In other examples, substantially the entire cartridge body 200 may be formed from one or more carbon materials (see, e.g., FIG. 5 ), which may offer advantages over other cartridge body configurations disclosed herein in terms of biodegradability and wire-free construction. In this regard, the heating element may include carbon foam, the reservoir may include carbonized fabric, and graphite may be employed to form electrical connections with the battery and controller. Examples of carbon-based cartridge bodies are described in U.S. Patent Application Publication No. 2015 / 0059780 to Davis et al. or U.S. Patent Application Publication No. 2013 / 0255702 to Griffith et al., both of which are incorporated herein by reference in their entireties. In some examples, the incorporation of a second aerosol generating device as disclosed herein may also be applied to such carbon-based cartridge bodies. For example, as shown in FIGS. 6A and 6B , a portion 625 of a cartridge element 600 positioned toward the mouthpiece of the cartridge body (see, e.g., FIG. 6A ) may be configured or modified to receive one or more of the aerosol generating elements 425 of the type disclosed herein (see, e.g., FIG. 6B ). Alternatively, a pre-assembled cartridge including such an aerosol generating element 425 may be implemented, or the cartridge element 600 and / or the outer body receiving the cartridge element 600 may be configured to receive first and second separation elements having an aerosol generating element therebetween, as disclosed herein.

[0120] 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. For example, one skilled in the art will understand that embodiments not expressly described herein may be practiced within the scope of the present disclosure, and that features described herein for other embodiments may be incorporated with each other and / or with known or future-developed technology, provided that they are within the scope of the appended claims. Accordingly, it is to be understood that the present disclosure is not limited to the specific embodiments disclosed herein, and that equivalents, modifications, and other embodiments are intended to be included within the scope of the appended claims.

Claims

1. An aerosol delivery system (100), comprising: a control body portion (300) including a first elongated tubular member having a first end and an opposing second end and a power source (316) disposed therein; a cartridge body (200) including a second tubular member having a first end engageable with a second end of the control body (300) and having an opposing second end, wherein the cartridge body (200) further comprises a first aerosol generating device (212) disposed within the second tubular member, the cartridge body (200) configured to operably engage a power source (316) upon engagement of the cartridge body (200) with the control body (300); a second aerosol generation device (400) comprising a housing body having a first end configured to engage the second end of the cartridge body portion (200) and a second end with a mouthpiece configured to define a mouth-engagement end (220) of the aerosol delivery system (100), the second aerosol generation device (400) also comprising a first separation element in the form of an air-permeable mesh screen incorporated into an enclosing portion of the housing body adjacent the first end of the housing body, a second separation element configured as a porous element and fixed to the mouthpiece, and a plurality of aerosol generation elements positioned between the first separation element and the second separation element; An aerosol delivery system (100) comprising:

2. 10. The aerosol product article of claim 1, wherein the plurality of aerosol-generating elements are selected from one or more of a sponge-like porous structure, fibers, flavor-releasing particles, flavor-retaining (and releasing) polymers, granules, co-crystals, powders, or microcapsules containing tobacco flavor or other substances in solid, gelatinous, colloidal, or gaseous form.

3. 3. The aerosol product article of claim 1 or 2, wherein the first and second separation elements are, independently of each other, one or both of heat conducting and air permeable.

4. 4. The aerosol delivery system of claim 1, wherein the first aerosol generating device comprises a liquid container disposed within the second tubular member and configured to receive an aerosol precursor material used by the first aerosol generating device to generate the first aerosol.

5. 5. The aerosol delivery system of claim 4, wherein the aerosol precursor material is one of glycerin, propylene glycol, water, saline, nicotine, an organic acid, and combinations thereof.

6. 6. The aerosol delivery system of claim 1, wherein the first aerosol generating device includes a heating element configured to provide heat for generating the first aerosol, and the plurality of aerosol generating elements of the second aerosol generating device are configured to interact with the heat and the first aerosol drawn therethrough into the mouth engaging end in response to suction applied to the mouth engaging end.

7. 7. The aerosol delivery system of claim 1, wherein the aerosol-generating element comprises one or more of granulated tobacco, tobacco extract, and nicotine, wherein the nicotine is in free base form, salt form, as a complex, or as a solvate.

8. 8. The aerosol delivery system of claim 1, wherein the aerosol generating element further comprises one or more flavoring agents.

9. 9. The aerosol delivery system of claim 1, wherein the second aerosol generating device (400) is removably engaged with the cartridge body (200).

10. 10. The aerosol delivery system of claim 9, wherein the second aerosol generating device (400) has a first connector (540) at a first end thereof, and the cartridge body portion (200) has a second connector (560) at a second end thereof, and the first connector (540) and the second connector (560) are configured to removably attach the second aerosol generating device (400) to the cartridge body portion (200).

11. 11. The aerosol delivery system of claim 1, wherein the second aerosol generating device (400) comprises a plurality of stackable, gas-permeable containers within a housing body.

12. 12. The aerosol delivery system of claim 11, wherein each container contains multiple aerosol generating elements.

13. 11. The aerosol delivery system of claim 1, wherein the housing body of the second aerosol generating device (400) has an internal compartment subdivided into multiple sub-compartments, each sub-compartment containing multiple aerosol generating elements.

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