RU2842077C1 - Electrically powered aerosol supply system - Google Patents

Abstract

FIELD: smoking accessories.

SUBSTANCE: aerosol supply system comprises a control housing part comprising a first elongated tubular element having opposite ends, and an energy source arranged therein, and a portion in the form of a cartridge body comprising a second tubular member having opposite first and second ends, wherein the first end is engaged with one of the opposite ends of the part in the form of a control body, the part in the form of the cartridge body further comprises a first aerosol generator arranged inside the second tubular element and configured to receive energy from the energy source after engagement between one of the opposite ends of the control housing part and the first end of the cartridge housing part, a second end of the cartridge body portion faces the mouth end of the aerosol delivery system; and a second aerosol generating device arranged between the first aerosol generating device and the mouth-interacting end of the aerosol delivery system, wherein the second aerosol generator is engaged with the cartridge body portion and is disengaged therefrom or disposed within the second tubular element of the cartridge body portion; wherein second aerosol generator comprises outer body and inner compartment divided into multiple sub-compartments to contain multiple aerosol-forming elements.

EFFECT: aerosol supply system enables to provide a user with the possibility of extracting an aerosol which is highly fragrant.

18 cl, 10 dwg

Description

PREREQUISITES FOR THE CREATION OF THE INVENTION

Field of technology

The present invention relates to aerosol delivery devices and systems, such as smoking articles; and more particularly, to aerosol delivery devices and systems that use electrically generated heat to produce an aerosol (e.g., smoking articles commonly referred to as electronic cigarettes). The aerosol delivery devices and systems may be configured to heat a substance to be aerosolized, comprising materials that may, although not necessarily, be made of or derived from tobacco or otherwise contain tobacco, and which are vaporizable to form an inhalable aerosol for human consumption.

State of the art

Over the years, a variety of smoking articles have been proposed as improvements to smoking articles or as alternatives to smoking articles that rely on the combustion of tobacco. Many of these have been specifically designed to provide the sensations associated with smoking a cigarette, cigar, or pipe without delivering significant amounts of the pyrolysis and incomplete combustion products that occur when tobacco is burned. To this end, numerous smoking articles, aroma generators, and medicinal inhalers have been proposed that use electrical energy to vaporize or heat a volatile material or to attempt to create the sensation of smoking a cigarette, cigar, or pipe without burning tobacco to a significant degree. See, e.g., the various alternative smoking articles, aerosol delivery devices, and heat generating sources set forth in the prior art and described in U.S. Patent No. 7,726,320 (Robinson et al.), U.S. Published Patent Application Nos. 2013/0255702 (Griffith Jr. et al.), and U.S. Published Patent Application Nos. 2014/0096781 (Sears et al.), the disclosures of which are incorporated herein by reference. See also, e.g., the various types of electrically powered smoking articles, aerosol delivery devices, and heat generating sources, the trade name and commercial source of which are referenced in U.S. Patent Application Ser. No. 14/170,838, filed February 3, 2014 (Bless et al.), the disclosures of which are incorporated herein by reference.

It would be desirable to provide a powered aerosol delivery system capable of providing a user of the system with the ability to draw an aerosol that is highly aromatic. It may also be desirable to deliver the aerosol in a pleasant or comfortable manner when drawn into the user's mouth.

Disclosure of the essence of the invention

The present invention relates to aerosol delivery systems. Such systems have the ability to generate an aerosol as a result of heat generated by electrical power sources and to deliver an aerosol intended for drawing into the mouth of a user. Of particular interest are aerosol delivery systems that provide tobacco components in aerosol form, delivered to smokers by devices commonly known or characterized as electronic cigarettes. As used herein, the term "aerosol" is intended to describe vapors, gases and aerosols in a form or type suitable for inhalation by a person, regardless of whether it is visible or not and regardless of whether it has a form that can be considered similar to smoke.

The above-mentioned and other needs are satisfied by the features of the present invention, which, according to one feature of the invention, provides an aerosol delivery system. Such an aerosol delivery system may comprise a part in the form of a control housing, wherein the part in the form of a control housing comprises a first elongated tubular element having opposite ends, and a power source placed therein. The part in the form of a cartridge housing comprises a second tubular element having opposite first and second ends. One of the first and second ends of the part in the form of a cartridge housing is detachably engaged with one of the opposite ends of the part in the form of a control housing. The part in the form of a cartridge housing further comprises a first device for generating an aerosol, placed inside the second tubular element and configured to functionally interact with the power source after engaging between one of the opposite ends of the part in the form of a control housing and one of the first and second ends of the part in the form of a cartridge housing. The other end of the first and second ends of the part in the form of a cartridge housing is further designed as an end interacting with the mouth. The part in the form of a cartridge body additionally contains a second device for generating an aerosol inside a second tubular element located between the first device for generating an aerosol and the end interacting with the mouth. According to certain features of the invention, the second aerosol generating device may further comprise one or more aerosol generating elements, wherein the one or more (at least one) aerosol generating elements may be selected from the group consisting of granules, tablets, spherical particles, discrete small particles, carbon pieces, molded carbon pieces, spherical ceramic particles, marumerized pieces of tobacco leaf, extruded or compressed cylindrical or spherical elements, shredded tobacco leaf, fillers, flavorings, visible aerosol forming materials, binders, ovoid elements, irregularly shaped elements, crushed pieces, flakes, tobacco-containing elements, elements containing visible aerosol forming material, objects made of adsorbent material, objects made of absorbent material, microcapsules, a honeycomb monolith, a single porous structure, and combinations thereof.

As another feature of the present invention, a method for forming an aerosol delivery system is proposed. Such a method may include releasably engaging one end of a first elongated tubular element with a first end of a second tubular element, wherein the first elongated tubular element is formed as a part in the form of a control housing with an energy source placed inside it, and the second tubular element is formed as a part in the form of a cartridge housing with a first device for generating an aerosol placed inside it. The first device for generating an aerosol is designed with the possibility of operatively engaging with the energy source after engaging between one end of the part in the form of a control housing and the first end of the part in the form of a cartridge housing. The method may also include inserting a second device for generating an aerosol inside the second tubular element of the part in the form of a cartridge housing, between the first device for generating an aerosol and the second end of the second tubular element, wherein the second end is opposite the first end and is formed as an end interacting with the mouth. In some cases, inserting the second aerosol generating device into the second tubular element may further comprise inserting one or more aerosol generating elements at least partially defining the second aerosol generating device into the second tubular element, wherein the one or more (at least one) aerosol generating elements may be selected from the group consisting of granules, tablets, spherical particles, discrete small particles, carbon pieces, molded carbon pieces, spherical ceramic particles, marumerized pieces of tobacco leaf, extruded or compressed cylindrical or spherical elements, shredded tobacco leaf, fillers, flavorings, visible aerosol-forming materials, binders, ovoid elements, irregularly shaped elements, crushed pieces, flakes, tobacco-containing elements, elements containing a visible aerosol-forming material, objects made of adsorbent material, objects made of absorbent material, microcapsules, a honeycomb monolith, a single porous structure, and their combinations.

Thus, the present invention includes, without limitation, the following embodiments:

Implementation option 1: An aerosol delivery system comprising

a part in the form of a control body containing

a first elongated tubular element having opposite ends, and

the energy source located within it; and

a part in the form of a cartridge body containing

a second tubular element having opposite first and second ends, wherein

one end of the first and second ends is detachably engaged with one of the opposite ends of the part in the form of a control body, wherein

the part in the form of a cartridge body additionally comprises a first device for forming an aerosol, located inside the second tubular element and configured to be functionally interacting with the energy source after engagement between one of the opposite ends of the part in the form of a control body and one end of the first and second ends of the part in the form of a cartridge body, wherein

the other end of the first and second ends of the part in the form of a cartridge body is, if necessary, additionally formed as an end interacting with the mouth, and

the part in the form of a cartridge body additionally contains a second device for generating an aerosol inside a second tubular element located between the first device for generating an aerosol and the end interacting with the mouth.

Embodiment 2: An aerosol delivery system according to any previous or subsequent embodiment of the present invention or combinations thereof, in which the second aerosol generating device further comprises at least one aerosol generating element.

Embodiment 3: An aerosol delivery system according to any preceding or following embodiment of the present invention or combinations thereof, wherein at least one aerosol forming element is selected from the group consisting of granules, tablets, spherical particles, discrete small particles, carbon pieces, molded carbon pieces, spherical ceramic particles, marumerized pieces of tobacco leaf, extruded or compressed cylindrical or spherical elements, shredded tobacco leaf, fillers, flavorings, visible aerosol forming materials, binders, ovoid elements, irregularly shaped elements, crushed pieces, flakes, tobacco-containing elements, elements containing visible aerosol forming material, objects made of adsorbent material, objects made of absorbent material, microcapsules, a honeycomb monolith, a single porous structure, and combinations thereof.

Embodiment 4: An aerosol delivery system according to any previous or subsequent embodiment of the present invention or combinations thereof, further comprising a first separating element located within the second tubular element between the first aerosol generating device and the second aerosol generating device, wherein

The first dividing element is a heat-conducting or air-permeable element.

Embodiment 5: An aerosol delivery system according to any preceding or following embodiment of the present invention or combinations thereof, wherein the first separating element extends along the longitudinal axis between the opposing ends to determine the thickness, and

the thickness of the first separating element is designed to form a gap between the second aerosol forming device and the heating element of the first aerosol forming device.

Embodiment 6: An aerosol delivery system according to any preceding or following embodiment of the present invention or combinations thereof, further comprising a second separating element located within the second tubular element between the second aerosol generating device and the mouth-interacting end, wherein

The second dividing element is a heat-conducting or air-permeable element.

Embodiment 7: An aerosol delivery system according to any preceding or following embodiment of the present invention or combinations thereof, wherein the second aerosol generating device comprises a cartridge having an elongated tubular body and opposing end members, and

each of the end elements is a heat-conducting or air-permeable element,

the elongated tubular body is made with the additional possibility of receiving at least one element for forming an aerosol and interacting with the opposite end elements to contain therein at least one element for forming an aerosol,

the cartridge is designed with the possibility of obtaining a second tubular element.

Embodiment 8: An aerosol delivery system according to any preceding or following embodiment of the present invention or combinations thereof, in which

the first aerosol forming device comprises a liquid reservoir located inside the second tubular element and configured to receive a substance to be aerosolized, used by the first aerosol forming device to generate a primary aerosol.

Embodiment 9: An aerosol delivery system according to any previous or subsequent embodiment of the present invention or combinations thereof, in which

The substance to be aerosolized is a substance that does not contain flavorings or acids.

Embodiment 10: An aerosol delivery system according to any preceding or following embodiment of the present invention or combinations thereof, in which

The substance to be aerosolized is one of the following: glycerin, propylene glycol, water, saline solution, nicotine, organic acids, or combinations thereof.

Embodiment 11: An aerosol delivery system according to any preceding or following embodiment of the present invention or combinations thereof, in which

the first aerosol forming device comprises a heating element configured to supply heat for forming a primary aerosol, and the second aerosol forming device comprises at least one aerosol forming element, wherein

at least one aerosol forming element is arranged to interact with heat and a primary aerosol drawn through it in the direction of the mouth interacting end in response to suction applied to the mouth interacting end in the cartridge body portion.

Embodiment 12: An aerosol delivery system according to any preceding or following embodiment of the present invention or combinations thereof, in which

at least one aerosol forming element of the second aerosol forming device is configured to interact with said heat from the heating element of the first aerosol forming device or the primary aerosol generated by the first aerosol forming device to form a secondary aerosol.

Embodiment 13: An aerosol delivery system according to any preceding or following embodiment of the present invention or combinations thereof, in which

the primary aerosol generated by the first aerosol generating device is configured to interact with the second aerosol generated by the second aerosol generating device to form a tertiary aerosol that is drawn toward the mouth-interacting end in response to suction applied thereto.

Embodiment 14: An aerosol delivery system according to any preceding or following embodiment of the present invention or combinations thereof, in which

at least one aerosol forming element of the second aerosol forming device is configured to interact with the primary aerosol and introduce an improving substance into the primary aerosol generated by the first aerosol forming device to form an improved aerosol drawn towards the mouth-interacting end in response to suction applied thereto.

Embodiment 15: An aerosol delivery system according to any preceding or following embodiment of the present invention or combinations thereof, in which

at least one aerosol forming element of the second aerosol forming device is configured to interact with the primary aerosol and remove heat from the primary aerosol generated by the first aerosol forming device to form a cooled aerosol drawn toward the mouth-interacting end in response to suction applied thereto.

Implementation option 16: An aerosol delivery system comprising:

a part in the form of a control body containing

a first elongated tubular element having opposite ends and an energy source located therein;

a part in the form of a cartridge body containing

a second tubular element having opposite first and second ends, wherein

the first end is engaged with one of the opposite ends of the part in the form of a control body,

the part in the form of a cartridge body additionally comprises a first device for forming an aerosol, located inside the second tubular element and configured to be functionally interacting with the energy source after engagement between one of the opposite ends of the part in the form of a control body and the first end of the part in the form of a cartridge body,

the second end of the cartridge body portion faces the mouth-interacting end of the aerosol delivery system; and

a second aerosol generating device positioned between the first aerosol generating device and the mouth-engaging end of the aerosol delivery system, wherein

the second device for forming an aerosol is either detachably engaged with the part in the form of a cartridge body or is located inside the second tubular element of the part in the form of a cartridge body.

Embodiment 17: An aerosol delivery system according to any previous or subsequent embodiment of the present invention, in which

the second aerosol forming device further comprises a plurality of elements for forming an aerosol in the form of spherical particles or tablets containing at least one aerosol forming material.

Embodiment 18: An aerosol delivery system according to any previous or subsequent embodiment of the present invention, in which

the aerosol forming elements additionally contain one or more components of tobacco in the form of particles, tobacco infusion and nicotine, wherein

Nicotine is available in free base form, in salt form, as a complex compound or solvate.

Embodiment 19: An aerosol delivery system according to any previous or subsequent embodiment of the present invention, in which

the aerosol forming elements additionally contain one or more fillers, binders, flavorings and combinations thereof.

Embodiment 20: An aerosol delivery system according to any previous or subsequent embodiment of the present invention, in which

Aerosol forming elements are treated with smoke.

Embodiment 21: An aerosol delivery system according to any preceding or following embodiment of the present invention, in which

the second aerosol generating device is located inside the second tubular element of the cartridge body part and comprises a plurality of elements for generating an aerosol in the form of spherical particles or tablets held in place by a first air-permeable separating element located inside the second tubular element between the first aerosol generating device and the second aerosol generating device and a second separating element between the second aerosol generating device and the mouth-interacting end.

Embodiment 22: An aerosol delivery system according to any preceding or following embodiment of the present invention, in which

the second aerosol generating device is detachably engaged with the cartridge housing portion and comprises a plurality of aerosol generating elements in the form of spherical particles or tablets held in place by a first air-permeable separating element between the first aerosol generating device and the second aerosol generating device and a second separating element between the second aerosol generating device and the mouth-interacting end.

Implementation option 23: A method for forming an aerosol supply system, including

releasably engaging one end of the first elongated tubular element with the first end of the second tubular element, wherein

the first elongated tubular element is formed as a part in the form of a control housing and contains an energy source placed therein,

the second tubular element is formed as a part in the form of a cartridge body and contains the first device for forming an aerosol placed therein,

the first device for forming an aerosol is designed with the possibility of functional interaction with the energy source after engagement between one end of the part in the form of a control body and the first end of the part in the form of a cartridge body; and

inserting a second aerosol forming device into the second tubular element of the cartridge body portion between the first aerosol forming device and the second end of the second tubular element, wherein

the second end is opposite the first end and is formed as the end interacting with the mouth.

Embodiment 24: A method according to any previous or subsequent embodiment of the present invention, in which

said operation of engaging the second aerosol forming device with the cartridge body portion comprises inserting the second aerosol forming device inside the second tubular element of the cartridge body portion, between the first aerosol forming device and the second end of the second tubular element, wherein

the second end is opposite the first end and is formed as the end interacting with the mouth.

Embodiment 25: A method according to any previous or subsequent embodiment of the present invention or combinations thereof, in which

inserting the second aerosol forming device into the second tubular element further comprises inserting at least one aerosol generating element that at least partially defines the second aerosol forming device into the second tubular element, wherein

at least one aerosol forming element is selected from the group consisting of granules, tablets, spherical particles, discrete small particles, carbon pieces, molded carbon pieces, spherical ceramic particles, marumerized pieces of tobacco leaf, extruded or compressed cylindrical or spherical elements, shredded tobacco leaf, fillers, flavorings, visible aerosol forming materials, binders, ovoid elements, irregularly shaped elements, crushed pieces, flakes, tobacco-containing elements, elements containing visible aerosol forming material, objects made of adsorbent material, objects made of absorbent material, microcapsules, a honeycomb monolith, a single porous structure, and combinations thereof.

Embodiment 26: A method according to any preceding or following embodiment of the present invention or combinations thereof, further comprising

inserting a first separating element into a second tubular element between the first aerosol forming device and the second aerosol forming device, wherein

The first dividing element is a heat-conducting or air-permeable element.

Embodiment 27: A method according to any preceding or following embodiment of the present invention or combinations thereof, further comprising

inserting a second separating element into the second tubular element between the second aerosol generating device and the mouth-engaging end of the cartridge body portion, wherein

The second dividing element is a heat-conducting and air-permeable element.

Embodiment 28: A method according to any preceding or following embodiment of the present invention or combinations thereof, in which

the second aerosol generating device comprises a cartridge having an elongated tubular body and opposing end members, wherein

each of the end elements is a heat-conducting or air-permeable element,

the elongated tubular body is made with the additional possibility of receiving at least one element for forming an aerosol and interacting with the opposite end elements to contain therein at least one element for forming an aerosol, and

inserting the second device for forming an aerosol further includes inserting the cartridge into the second tubular element of the part in the form of a cartridge body.

Implementation option 29: A method for forming an aerosol supply system, comprising:

engaging one end of the first elongated tubular element with the first end of the second tubular element, wherein

the first elongated tubular element is designed as a part in the form of a control housing and contains a power source placed therein, and

the second tubular element is designed as a part in the form of a cartridge body and contains the first device for forming an aerosol placed therein,

the first device for forming an aerosol is designed with the possibility of functional interaction with the energy source after engagement between one end of the part in the form of a control body and the first end of the part in the form of a cartridge body,

the second end of the part in the form of a cartridge body faces the end of the aerosol delivery system interacting with the mouth;

and engaging the second aerosol generating device with the cartridge housing portion such that the second aerosol generating device is positioned between the first aerosol generating device and the mouth-interacting end of the aerosol delivery system.

Embodiment 30: A method according to any previous or subsequent embodiment of the present invention, in which

the second aerosol generating device comprises a plurality of elements for generating an aerosol in the form of spherical particles or tablets held in place by a first air-permeable separating element located within a second tubular element between the first aerosol generating device and the second aerosol generating device and a second separating element between the second aerosol generating device and the mouth-interacting end.

Embodiment 31: A method according to any previous or subsequent embodiment of the present invention, in which

said operation of engaging the second device for forming an aerosol with the part in the form of a cartridge body includes releasably engaging the second device for forming an aerosol with the part in the form of a cartridge body,

the second aerosol generating device comprises a first end configured to be releasably engaged with a portion in the form of a cartridge body, and a second end adapted to form the mouth-interacting end of the aerosol delivery system, and

in which

the second aerosol generating device comprises a plurality of aerosol generating elements in the form of spherical particles or tablets held in place by a first air-permeable separating element between the first aerosol generating device and the second aerosol generating device and a second separating element between the second aerosol generating device and the mouth-interacting end.

Embodiment 32: A method according to any previous or subsequent embodiment of the present invention, in which

the second aerosol generating device comprises a plurality of elements for generating an aerosol in the form of spherical particles or tablets containing at least one aerosol-forming material.

Embodiment 33: A method according to any previous or subsequent embodiment of the present invention, in which

the aerosol forming elements additionally contain one or more components of tobacco in the form of particles, tobacco infusion and nicotine, wherein

Nicotine is available in free base form, in salt form, as a complex compound or solvate.

Embodiment 34: A method according to any previous or subsequent embodiment of the present invention, in which

the aerosol forming elements additionally contain one or more fillers, binders, flavorings and combinations thereof.

Embodiment 35: A method according to any previous or subsequent embodiment of the present invention, in which

Aerosol forming elements are treated with smoke.

Implementation option 36: An aerosol delivery system comprising:

a part in the form of a control body containing

a first elongated tubular element having opposite ends and an energy source located therein;

a part in the form of a cartridge body containing

a second tubular element having opposite first and second ends, wherein

the first end is engaged with one of the opposite ends of the part in the form of a control body,

the part in the form of a cartridge body additionally comprises a first device for forming an aerosol, located inside the second tubular element and configured to be functionally interacting with the energy source after engagement between one of the opposite ends of the part in the form of a control body and the first end of the part in the form of a cartridge body,

the second end of the cartridge body portion faces the mouth-interacting end of the aerosol delivery system; and

a second aerosol generating device positioned between the first aerosol generating device and the mouth-engaging end of the aerosol delivery system, wherein

the second device for forming an aerosol is either detachably engaged with the part in the form of a cartridge body or is located inside the second tubular element of the part in the form of a cartridge body, wherein

the second aerosol generating device further comprises a plurality of elements for generating an aerosol in the form of spherical particles or tablets.

Embodiment 37: An aerosol delivery system according to any previous or subsequent embodiment of the present invention or combinations thereof, wherein the second aerosol generating device comprises an outer housing body and a plurality of stackable gas-permeable containers inside the outer housing body, each container comprising a plurality of aerosol generating elements.

Embodiment 38: An aerosol delivery system according to any previous or subsequent embodiment of the present invention or combinations thereof, wherein the second aerosol generating device comprises an outer housing body and an inner compartment divided into a plurality of sub-compartments, each of the sub-compartments comprising a plurality of aerosol generating elements.

Embodiment 39: An aerosol delivery system according to any previous or subsequent embodiment of the present invention or combinations thereof, wherein the spherical particles or tablets comprise a support material selected from the group consisting of spherical glass particles, fibers, honeycomb structures, porous monoliths, and spherical polymer particles.

Embodiment 40: An aerosol delivery system according to any previous or subsequent embodiment of the present invention or combinations thereof, wherein each spherical particle or tablet is made in the form of an extruded material containing a particulate material selected from tobacco material and filler, at least one aerosol-forming material, and at least one binder material.

Embodiment 41: An aerosol delivery system according to any of the previous embodiments, or a combination thereof, in which the aerosol forming elements additionally contain one or more flavoring agents.

These and other features, aspects and advantages of the present invention will be apparent from reading the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four or more of the above-mentioned embodiments, as well as combinations of any two, three, four or more features or elements set forth in this disclosure, regardless of whether such features or elements are explicitly combined in a particular embodiment described herein. This disclosure is intended to be read as a whole, such that any individual features or elements of the disclosed invention, in any of its various aspects and embodiments, should be considered as capable of being combined unless the context clearly indicates otherwise.

Brief description of the drawings

The invention has been described above in general terms; reference will now be made to the accompanying drawings, which are not necessarily drawn to scale and in which:

Fig. 1 schematically shows an aerosol delivery device comprising a cartridge housing and a control housing, wherein the cartridge housing is shown in a disassembled configuration and the control housing is shown in an assembled configuration according to an exemplary feature of the present invention;

Fig. 2 schematically shows the control housing of Fig. 1 in an exploded configuration according to an exemplary feature of the present invention.

Fig. 3 schematically shows the housing of the cartridge of Fig. 1, implementing an additional device for generating an aerosol, containing one or more elements for generating an aerosol, according to one aspect of the present invention.

Fig. 4 schematically shows an additional device for generating an aerosol according to Fig. 3, made in the form of a cartridge containing one or more elements for generating an aerosol according to another feature of the present invention;

Fig. 5 is a schematic exploded view of an alternative carbon-based cartridge housing according to an exemplary aspect of the present invention.

Fig. 6A is a schematic view of the assembled carbon-based cartridge housing of Fig. 5 according to an exemplary aspect of the present invention;

Fig. 6B is a schematic illustration of an assembled carbon-based cartridge housing implementing an additional aerosol generating device including one or more aerosol generating elements according to one aspect of the present invention.

Fig. 7 is a sectional view of a second aerosol generating device housed within the same outer housing as the first aerosol generating device, according to an exemplary aspect of the present invention; Fig. 8 is a sectional view of a second aerosol generating device removably attached to an outer housing housing the first aerosol generating device, according to an exemplary aspect of the present invention.

Fig. 9 shows a sectional view of a second aerosol generating device comprising a plurality of stackable components; and

Fig. 10 shows a top view of a device for forming an aerosol in the form of a plurality of wedges.

Detailed description of preferred embodiments of the invention

The present invention will now be described in more detail with reference to exemplary embodiments thereof. These exemplary embodiments are described so that this disclosure will be thorough and complete and will fully disclose the scope of the present invention to those skilled in the art. Indeed, this invention may be embodied in many different forms and should not be considered as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure satisfies applicable legal requirements. As used in the specification and the appended claims, the singular includes the plural unless the context clearly indicates otherwise.

As described further, features of the present invention relate to aerosol delivery systems. Aerosol delivery systems according to the present invention use electrical energy to heat a material (in a preferred embodiment without burning the material to any significant extent) to form a respirable substance; and components of such systems have an article form that is preferably compact enough to consider such systems as handheld devices. Thus, use of components of the preferred aerosol delivery systems does not result in the generation of smoke in the sense that the aerosol arises primarily from by-products of combustion or pyrolysis of tobacco, but rather, use of these preferred systems results in the generation of vapors (including vapors within aerosols that may be considered visible/invisible aerosols, which may be considered to be described as smoke-like) arising from the evaporation or vaporization of certain components included therein. In embodiments of preferred features of the invention, the components of the aerosol delivery systems may be characterized as electronic cigarettes, and most preferably, these electronic cigarettes contain tobacco and/or components derived from tobacco and, therefore, deliver tobacco-derived components in aerosol form.

Aerosol generating devices in certain preferred aerosol delivery systems are capable of providing many of the sensations (e.g., inhalation and exhalation rituals, taste or aroma types, organoleptic effects, physical sense, rituals of use, visual cues such as those provided by a visible aerosol, etc.) of smoking a cigarette, cigar, or pipe that occur when tobacco is ignited and burned (and hence when tobacco smoke is inhaled), without any significant degree of combustion of any component thereof. For example, a user of an aerosol generating device according to the present invention can hold and use the device in much the same way as a smoker uses a traditional type of smoking article, by puffing on one end of the article to inhale the aerosol generated by the article, puffing at selected time intervals, etc.

The aerosol delivery systems of the present invention can also be characterized as suitable vapor-generating articles, aerosol-generating articles or medicament-delivering articles. Thus, such articles, systems or devices can be adapted to deliver one or more substances (e.g., flavors, pharmaceutically active ingredients, peptides, protein fragments and/or protein shells) in a form or state suitable for inhalation. For example, the respirable substances can be essentially in the form of a vapor (i.e., a substance present in the gas phase at a temperature below its critical point). Alternatively, the respirable substance can be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). For purposes of simplicity, the term "aerosol" as used herein is intended to describe vapors, gases, mists and/or solid particles in a form or type suitable for inhalation by humans, whether or not visible and whether or not in a form that may be considered smoke-like.

Aerosol delivery systems according to the present invention most preferably comprise some combination of a power source (i.e., a power source), at least one control component (e.g., means for actuating, controlling, regulating, and stopping the supply of power for generating heat, such as by controlling an electric current from the power supply source to other components of the aerosol generating device), a heating element or heat generating component (e.g., an electrical resistance heating element and associated components, commonly referred to as providing an "atomizer"), and a composition of the substance to be aerosolized (e.g., typically a liquid capable of generating an aerosol upon the application of sufficient heat, such as ingredients commonly referred to as "smoke juice," "e-liquid," and "e-juice"), and a mouthpiece region, mouth-engaging end, or tip configured to tighten the aerosol delivery system for inhaling aerosols (e.g., in a specific air flow path through the aerosol generating device such that the generated aerosol can be recovered therefrom by tightening).

More specific formats, configurations, and arrangements of the components of the articles within the aerosol delivery systems of the present invention will be apparent in light of the further disclosure provided herein. In addition, the selection and arrangement of the various components of the aerosol delivery system can be appreciated by considering commercially available electronic aerosol delivery devices, such as those representative articles mentioned in the "Background of the Art" section of the present description.

According to certain features of the invention, the aerosol delivery devices according to the present invention, when used, can be subjected to many of the physical actions used by a person when using a traditional type of smoking article (for example, a cigarette, cigar or pipe, which are used by lighting and inhaling tobacco). For example, a user of the aerosol delivery device according to the present invention can hold this article like a traditional type of smoking article, taking a puff on one end of this article to inhale the aerosol generated by this article, taking puffs at selected time intervals, etc.

One such example of an aerosol delivery system 100 is illustrated in Fig. 1. In particular, Fig. 1 shows a partially exploded view of an aerosol delivery system 100 that includes a cartridge housing 200 and a control housing 300 (otherwise referred to herein as the "cartridge housing portion" and the "control housing portion," respectively). The cartridge housing 200 and the control housing 300 may be permanently or removably oriented or releasably engaged in an operative relationship. Various means may be used to connect the cartridge housing 200 to the control housing 300, resulting in a threaded engagement, a press fit engagement, an interference fit, a magnetic engagement, and the like. The aerosol delivery system 100 may be substantially rod-like, substantially pipe-shaped, or substantially cylindrical in some embodiments of the present invention in the assembled configuration of the cartridge housing 200 and the control housing 300. As used herein, the term "tubular" refers to a hollow elongated body, but is not limited to a specific cross-sectional shape or a specific outer contour of the body. Those skilled in the art will also understand that in some cases, although not described in detail herein, the cartridge housing 200 and the control housing 300 that form the aerosol delivery system 100 may be formed as a single, integral object and may include components, features, and properties associated with and disclosed in this disclosure.

In some cases, one or both elements of the cartridge housing 200 and the control housing 300 may be referred to as disposable (i.e., as a previously described single non-detachable object) or reusable. For example, the reusable control housing 300 may have a replaceable battery or a rechargeable battery and, thus, may be combined with any type of recharging technology, including a connection to a regular electrical outlet, a connection to a car charger (i.e., a cigarette lighter socket) and a connection to a computer, for example, via a USB cable. Typically, the aerosol delivery system of the type disclosed herein comprises a battery or other power source for supplying an electric current sufficient to implement various functional features of the article, such as power supply of a heater or a heating element, power supply of control systems, power supply of indicators, etc. The power source may have various embodiments. In a preferred embodiment, the energy source is capable of delivering sufficient power to rapidly heat the heating element to provide aerosol formation and to power the article through use for a desired length of time. The energy source is preferably sized to fit comfortably within the aerosol delivery device/system such that the aerosol delivery device/system can be easily handled; and, further, the preferred energy source is light enough to not detract from the desired smoking experience. Furthermore, in some cases, the cartridge housing 200 may comprise a disposable cartridge, as disclosed, for example, in U.S. Patent Application Publication No. 2014/0060555 (Chang et al.), the contents of which are incorporated herein by reference in their entirety.

Fig. 2 shows an exploded view of a control housing 300 of an aerosol delivery system 100 according to another example. As shown, the control housing 300 may include a coupling device 302, an outer housing 304, a sealing element 306, an adhesive element 308 (e.g., KAPTON® adhesive tape), a flow sensor 310 (e.g., a puff sensor or a pressure switch), a control component 312, a spacer 314, a power source 316 (e.g., a battery that can be configured to be rechargeable), a circuit board with an indicator 318 (e.g., with an LED), a circuit 320 of a connecting device, and an end cap 322. Examples of power sources are described in U.S. Patent Application Publication No. 2010/0028766 (Peckerar et al.), the contents of which are incorporated herein by reference in their entirety.

With respect to flow sensor 310, typical current regulating components and other current controlling components, including various microcontrollers, sensors, and switches for aerosol delivery devices/systems, are described, for example, in U.S. Patent Nos. 4,735,217 (Gerth et al.); 4,947,874 (Brooks et al.); 5,372,148 (McCafferty et al.); 6,040,560 (Fleischhauer et al.); 7,040,314 (Nguyen et al.); and 8,205,622 (Pan); U.S. Patent Publication Nos. 2009/0230117 (Fernando et al.); 2014/0060554 (Collett et al.); and 2014/0270727 (Ampolini et al.), and U.S. Patent Application No. 14/209,191, filed March 13, 2014 (Henry et al.), the contents of which are incorporated herein by reference.

In some cases, the indicator 318 may comprise one or more light-emitting diodes. The indicator 318 may be in communication with the control component 312 via the circuit 320 of the connecting device and illuminate, for example, during a puff by the user on the cartridge housing 200, connected to the connecting device 302, as detected by the flow sensor 310. The end cap 322 may be adapted to provide visibility of the illumination provided by the indicator 318 underneath. Accordingly, the indicator 318 may illuminate during use of the aerosol delivery system 100 to simulate a lit end of the smoking article. However, in other cases, the indicator 318 may be provided in different quantities and may take different shapes and may even be an opening in the outer housing (for example, for releasing a sound, if such indicators are present). Additional representative types of components that provide visual information or indicators, such as LED components, and their configuration and use are described in U.S. Patents 5,154,192 (Sprinkel et al.); 8,499,766 (Newton); and 8,539,959 (Scatterday); and U.S. Patent Application Ser. No. 14/173,266, filed February 5, 2014 (Sears et al.); the contents of which are incorporated herein by reference.

Additional features, controls, or components that may be included in the aerosol delivery devices and systems of the present invention are described in U.S. Patent Nos. 5,967,148 (Harris et al.); 5,934,289 (Watkins et al.); 5,954,979 (Counts et al.); 6,040,560 (Fleischhauer et al.); 7,726,320 (Robinson et al.); 8,365,742 (Hon); 8,402,976 and 8,689,804 (Fernando et al.); and U.S. Patent Application Published Nos. 2013/0192623 (Tucker et al.); 2013/0298905 (Leven et al.); 2013/0180553 (Kim et al.) and 2014/0000638 (Sebastian et al.); and in U.S. Patent Application Publication Nos. 2014/0261495 (Novak, III et al.) and 2014/0261408 (DePiano et al.); the entire contents of which are incorporated herein by reference.

Returning to Fig. 1, the cartridge housing 200 is shown in an exploded configuration. As shown, the cartridge housing 200 may comprise a base transport plug 202, a base 204, a control component clamp 206, an electronic control component 208, a flow tube 210, an atomizer 212, a reservoir substrate 214, an outer shell 216, a sticker 218, a mouthpiece 220 and a mouthpiece transport plug 222 according to an exemplary embodiment of the present invention. The base 204 may be connected to a first end of the outer shell 216, and the mouthpiece 220 may be connected to an opposite second end of the outer shell 216 to enclose the remaining components of the cartridge housing 200. The base 204 may be configured to releasably engage the coupling device 302 of the control body 300. In some cases, the base 204 may comprise anti-rotation means that substantially prevent relative rotation between the cartridge body and the control body, as disclosed in U.S. Patent Application Publication No. 2014/0261495 (Novac, III et al.), the contents of which are incorporated herein by reference in their entirety. Various exemplary coupling arrangements for upstream and downstream components of electronic cigarettes have been set forth in the patent literature and used to produce commercially available electronic cigarettes. For example, exemplary types of coupling arrangements and components for electronic cigarettes are described in U.S. Patent Application Publication No. 2014/0261495 (Novac, III et al.) and U.S. Patent Application No. No. 14/170,838, filed February 3, 2014 (Bless et al.); the contents of which are incorporated herein by reference.

The transport plug 202 of the base can be configured to engage with the base 204 and protect it until the cartridge housing 200 is used. Similarly, the transport plug 222 of the mouthpiece can be configured to engage with the mouthpiece 220 and protect it until the cartridge housing 200 is used. The control component clip 206, the electronic control component 208, the flow tube 210, the atomizer 212 and the reservoir substrate 214 (interaction with the composition or substance to be aerosolized) can be stored inside the outer shell 216. The sticker 218 can at least partially surround the outer shell 216 and contain information such as a product identifier.

The orientation of the components within either the control housing or the cartridge housing of the aerosol delivery device/system, or both housings, may vary. As certain features of the invention, the composition to be aerosolized may be located near one end of the complete article (e.g., within the cartridge housing, which may be replaceable and disposable under certain circumstances), which may be configured to be positioned relatively close to the user's mouth to maximize the delivery of the aerosol to the user. However, other configurations are not excluded. Typically, the heating element may be positioned close enough to the composition to be aerosolized such that heat from the heating element is capable of atomizing the substance to be aerosolized (and/or one or more flavors, medications, etc., which may similarly be provided for delivery to the user) and forming an aerosol for delivery to the user. When the heating element heats the composition to be aerosolized, the aerosol is formed, released, or produced in a physical form suitable for inhalation by the consumer. It should be noted that the preceding terms are intended to be interchangeable, so that the use of the terms "release, release, releases or released" is equivalent to the terms "form or generate, formation or generation, forms or generates, and formed or generated." In particular, the respirable substance is released in the form of a vapor or an aerosol or a mixture thereof. In addition, the selection of various components of the aerosol delivery device can be assessed after considering commercially available electronic aerosol delivery devices, such as the representative articles mentioned above in this description.

The atomizer (i.e., the aerosol generating device) 212 may comprise a first clamp 234a of the heating element and a second clamp 234b of the heating element, a liquid transfer element 238 and a heating element 240. In this regard, the reservoir and/or the substrate 214 of the reservoir may be configured to contain a composition to be aerosolized. The composition to be aerosolized, also referred to as a composition to be converted into vapor, may comprise a plurality of components in various aspects. Such components may include, by way of example, any polyhydric alcohol (for example, glycerin, propylene glycol or a mixture thereof), nicotine, tobacco, tobacco infusion, water, flavorings and combinations thereof.

The composition to be aerosolized or the composition to be converted into a vapor may be different. Most preferably, the composition to be aerosolized consists of a combination or mixture of different ingredients or components. The choice of certain components of the substance to be aerosolized and the relative amounts of these components used can be varied to control the overall chemical composition of the primary aerosol formed by the aerosol generating device(s). Of particular interest are compositions to be aerosolized that can be characterized as generally liquid in nature. For example, typical, generally liquid, compositions to be aerosolized can be in the form of liquid solutions, viscous gels, mixtures of soluble components, or liquids containing suspended or dispersed components. Typical compositions to be aerosolized are capable of vaporizing when exposed to heat under the conditions that occur during use of the aerosol generating device(s) that are characteristic according to the present invention; and are therefore capable of producing vapours and aerosols suitable for inhalation.

For aerosol delivery systems characterized as electronic cigarettes, the composition to be aerosolized most preferably comprises tobacco or tobacco-derived components. In one respect, the tobacco may be provided in the form of tobacco pieces or pieces, such as finely divided, ground or powdered tobacco leaf. In another respect, the tobacco may be provided in the form of an extract, such as a spray-dried extract containing many of the water-soluble components of tobacco. Alternatively, the tobacco extracts may be in the form of extracts having a relatively high nicotine content, the extracts also containing minor amounts of other extracted components derived from tobacco. In another respect, the tobacco-derived components may be provided in relatively pure form, such as certain flavoring agents derived from tobacco. In one respect, a tobacco-derived component that may be used in a highly purified or extremely pure form is nicotine (e.g., pharmaceutical grade nicotine).

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

The composition to be aerosolized may also contain so-called "aerosol-forming materials". In some cases, such materials are capable of having the ability to generate a visible (or invisible) aerosol when evaporated under the influence of heat under the conditions occurring during normal operation of the aerosol-forming device(s), which are characteristic according to the present invention. Such aerosol-forming materials include various polyols or polyhydric alcohols (for example, glycerin, propylene glycol and mixtures thereof). Features of the present invention also include components of the substance to be aerosolized, which can be characterized as water, a saline solution, moisture or an aqueous liquid. During normal operating conditions of a certain aerosol-forming device(s), water enclosed within this aerosol-forming device(s) can be evaporated to form a component of the generated aerosol. Also, for the purposes of the present invention, water present within the composition to be aerosolized can be considered an aerosol-forming material.

A wide variety of optional flavoring agents or materials may be used to alter the sensory character or nature of the elongated primary aerosol generated by the aerosol delivery system of the present invention. For example, such optional flavoring agents may be used within the composition or substance to be aerosolized to alter the aroma, odor, and organoleptic properties of the aerosol. Certain flavoring agents may be derived from sources other than tobacco. Exemplary flavoring agents may be natural or artificial in nature and may be used in the form of concentrates or flavor packages.

Examples of flavoring agents include vanillin, ethyl vanillin, cream, tea, coffee, fruit (such as 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, croton wood, cocoa, licorice, and flavorings and flavor packs of the type and character traditionally used to flavor cigarettes, cigars, and pipe tobaccos. Molasses such as high fructose corn syrup may also be used. Certain flavoring agents may be incorporated into the aerosol-forming materials prior to forming the final mixture of the substance to be aerosolized (e.g., certain water-soluble flavoring agents may be incorporated into water, menthol may be incorporated into propylene glycol, and certain complex flavor packages may be incorporated into propylene glycol). However, according to certain aspects of the present invention, the composition to be aerosolized may not contain any flavoring agents, flavor characteristics, or additives.

Aerosolizable compositions may also include ingredients exhibiting acidic or basic characteristics (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 the formulation of an aerosolizable substance comprising nicotine, preferably in amounts up to equimolar (based on the total organic acid content) with nicotine. For example, the aerosolizable substance may comprise from about 0.1 to about 0.5 moles of levulinic acid per mole of nicotine, from about 0.1 to about 0.5 moles of pyruvic acid per mole of nicotine, from about 0.1 to about 0.5 moles of lactic acid per mole of nicotine, or combinations thereof, up to a concentration at which the total amount of organic acid present is equimolar to the total amount of nicotine present in the aerosolizable substance. However, according to certain aspects of the present invention, the aerosolizable composition may not have any acidic (or basic) characteristic or additives.

As a non-limiting example, a representative aerosolizable composition or substance may include glycerin, propylene glycol, water, a saline solution, and nicotine, and combinations or mixtures of any or all of these components. For example, in one example, a representative aerosolizable composition may comprise (by weight) from about 70% to about 100% glycerin, and often from about 80% to about 90% glycerin; from about 5% to about 25% water, often from about 10% to about 20% water; and from about 0.1% to about 5% nicotine, often from about 2% to about 3% nicotine. In one specific non-limiting example, a representative aerosolizable composition may comprise about 84% glycerin, about 14% water, and about 2% nicotine. A typical aerosolizable composition may also contain propylene glycol, additional flavoring agents, or other additives in varying amounts on a weight basis. In some cases, the aerosolizable composition may include, as needed or desired, up to about 100% by weight of any one of glycerin, water, and saline.

Representative types of aerosolizable substance components and formulations are also set forth and characterized in U.S. Patent No. 7,217,320 (Robinson et al.) and Patent Publication Nos. 2013/0008457 (Zheng et al.); 2013/0213417 (Chong et al.) and 2014/0060554 (Collett et al.), the contents of which are incorporated herein by reference. Other aerosolizable substances that may be used include aerosolizable substances that have been incorporated into the VUSE® product of R. J. Reynolds Vapor Company, the BLUTM product of Lorillard Technologies, the MISTIC MENTHOL product of Mistic Ecigs, and the VYPE CN product of Creative Ltd. Also desirable are the so-called "smoke juices" for electronic cigarettes produced by Johnson Creek Enterprises LLC.

The amount of the aerosolizable substance contained within the aerosol delivery system is such that the aerosol generating device(s) provides acceptable sensory and desired performance characteristics. For example, it is highly preferred that sufficient amounts of the aerosol forming material (e.g., glycerin and/or propylene glycol) are used to provide a primary aerosol (visible or not) that in many respects resembles the appearance of tobacco smoke. The amount of the aerosolizable composition within the aerosol generating device(s) may depend on factors such as the desired number of puffs per aerosol generating device. Typically, the amount of the aerosolizable composition included in the aerosol delivery system and, in particular, in the aerosol generating device(s) is less than about 2 g, typically less than about 1.5 g, often less than about 1 g, and often less than about 0.5 g.

The reservoir substrate 214 may comprise a plurality of layers of nonwoven fibers formed in the form of a tube surrounding the interior of the outer shell 216 of the cartridge housing 200. In this manner, liquid components, for example, may be retained in the reservoir substrate 214 by sorption. The reservoir substrate 214 is fluidly connected to a liquid transfer element 238. The liquid transfer element 238 may be configured to transfer liquid (i.e., the compositions to be aerosolized) from the reservoir substrate 214 to the heating element 240 by capillary action. Representative types of substrates, reservoirs, or other components for supporting the compositions to be aerosolized are described in U.S. Patent No. 8,528,569 (Newton); in U.S. Patent Application Publication Nos. 2014/0261487 (Chapman et al.) and 2015/0059780 (Davis et al.); and in U.S. Patent Application Ser. No. 14/170,838, filed February 3, 2014 (Bless et al.); the contents of which are incorporated herein by reference. Additionally, various wicking materials, as well as the configuration and operation of these wicking materials within certain types of electronic cigarettes, are described in U.S. Patent Application Publication No. 2014/0209105 (Sears et al.); the contents of which are incorporated herein by reference.

As shown, the liquid transfer element 238 may be in direct contact with the heating element 240. As further shown in Fig. 1, the heating element 240 may comprise a wire defining a plurality of turns wound around the liquid transfer element 238. In some cases, the heating element 240 may be formed by winding a wire around the liquid transfer element 238, as described in U.S. Patent Application Publication No. 2014/0157583 (Ward et al.), the contents of which are incorporated herein by reference in their entirety. Furthermore, in some cases, the wire may define a variable distance between turns, as described in U.S. Patent Application Publication No. 2014/0270730 (DePiano et al.), the contents of which are incorporated herein by reference in their entirety. Various materials capable of generating heat when an electric current is applied thereto can be used to form the heating element 240. Exemplary materials from which the wire coil can be formed include kanthal (FeCrAl), nichrome, molybdenum disilicide (MoSi ₂ ), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al) ₂ ), graphite and graphite-based materials; and ceramics (e.g., ceramics with a positive or negative temperature coefficient).

However, various other methods may be used to form the heating element 240, and various other features of the heating elements may be used in the atomizer 212. For example, a stamped heating element may be used in the atomizer as described in U.S. Patent Application Publication No. 2014/0270729 (DePiano et al.), the contents of which are incorporated herein by reference in their entirety. In addition to the above, additional representative heating elements and materials for use therein are described in U.S. Patent No. 5,060,671 (Counts et al.); U.S. Patent No. 5,093,894 (Deevi et al.); U.S. Patent No. 5,224,498 (Deevi et al.); U.S. Patent No. 5,228,460 (Sprinkel Jr. et al.); US Patent No. 5,322,075 (Deevi et al.); US Patent No. 5,353,813 (Deevi et al.); US Patent No. 5,468,936 (Deevi et al.); US Patent No. 5,498,850 (Das); US Patent No. 5,659,656 (Das); US Patent No. 5,498,855 (Deevi et al.); US Patent No. 5,530,225 (Hajaligol); US Patent No. 5,665,262 (Hajaligol); US Patent No. 5,573,692 (Das et al.); and U.S. Patent No. 5,591,368 (Fleischhauer et al.), the contents of which are incorporated herein by reference in their entirety. In addition, chemical heating can be used as other features of the present invention. Different components of the heating element can also be used as certain features of the present aerosol delivery device/system. In various cases, one or more microheaters or similar solid-state heating elements can be used. Exemplary microheaters that can be used are further described herein. Other microheaters and atomizers containing microheaters suitable for use in the presently disclosed devices/systems are described in U.S. Patent Application Publication No. 2014/0060554 (Collett et al.), the contents of which are incorporated herein by reference in their entirety.

The first clamp 234a of the heating element and the second clamp 234b of the heating element (e.g., positive and negative clamps) at opposite ends of the heating element 240 are configured to form an electrical connection (which may be a removable or detachable connection) with the control body 300 when the body 200 of the cartridge is connected thereto. In addition, when the control body 300 is connected to the body 200 of the cartridge, the electronic control component 208 is capable of forming an electrical connection with the control body 300 through the clamp of the control component 206. The control body 300 is thus capable of using the electronic control component 208 to determine the authenticity of the cartridge 200 and/or to perform other functions. In addition, various examples of electronic control components and the functions performed by them are described in US Patent Application Publication No. 2014/0096781 (Sears et al.), the contents of which are incorporated herein by reference in their entirety.

During use, the user may draw on the mouthpiece or on the mouth-engaging end 220 of the cartridge housing 200 of the aerosol delivery system 100. This may involve drawing air through an opening in the control housing 300 and/or in the cartridge housing 200. For example, in one case, the opening may be formed between the coupling device 302 and the outer shell 304 of the control housing 300, as described in US Patent Application Publication No. 2014/0261408 (DePiano et al.), the contents of which are incorporated herein by reference in their entirety. However, in other embodiments of the present invention, the air flow may be obtained through other parts of the aerosol delivery device/system 100. As noted above, according to certain features of the invention, the cartridge housing 200 may comprise a flow tube 210. The flow tube 210 may be configured to direct the air flow received from the control housing 300 to the heating element 240 of the atomizer 212.

A sensor in the aerosol delivery device/system 100 (e.g., a puff or flow sensor in the control body 300) is capable of sensing a puff. More generally, the sensor or detector can be implemented to control the supply of electrical power to the heating element 240 when needed to generate an aerosol (e.g., when puffing during use). Also, for example, a course of action or method is provided for turning off the supply of electrical power to the heating element 240 when there is no need for aerosol generation during use, and for turning on the supply of electrical power to activate the start of heat production by the heating element 240 during a puff. Additional representative types of sensing and detecting devices, their structures and configurations, their components and general methods of their operation are described in U.S. Pat. Nos. 5,261,424 (Sprinkel, Jr.); 5,372,148 (McCafferty et al.); and in PCT application WO 2010/003480 (Fick); the contents of which are incorporated herein by reference in their entirety. Upon sensing a puff, the control body 300 is configured to direct current to the heating element 240 through a circuit comprising a first heating element terminal 234a and a second heating element terminal 234b. Accordingly, the heating element 240 is configured to vaporize a composition to be aerosolized, directed toward the aerosolization zone from the reservoir substrate 214 by the liquid transfer element 238. In this manner, the mouthpiece 220 may allow air and entrained vapor (i.e., components of the composition to be aerosolized in a form suitable for inhalation, such as in the form of an aerosol) to pass from the cartridge body 200 to a consumer who puffs on it. Various other details regarding components that may be included in the cartridge housing 200 are given, for example, in U.S. Patent Application Publication No. 2014/0261495 (Novac, III et al.), the contents of which are incorporated herein by reference in their entirety.

Various components of the aerosol delivery device/system may be selected from components described in the prior art and commercially available. For example, reference is made to a reservoir and a heating element system for controlled delivery of multiple aerosolizable materials in an electronic smoking article disclosed in U.S. Patent Application Publication No. 2014/0000638 (Sebastian et al.), the contents of which are incorporated herein by reference in their entirety. In addition, it should be noted that the parts of the cartridge housing 200 shown in Fig. 1 are not required. In this regard, as an example, it should be noted that the cartridge housing 200 in some cases does not necessarily include the flow tube 210, the clamp 206 of the control component 206 and/or the electronic control component 208.

One specific feature according to the present invention is explained, for example, in Fig. 3. In such cases, the cartridge housing 200 may further comprise a second aerosol generating device 400 (the atomizer 212 is considered as the "first aerosol generating device"), located in the outer shell 216 in the longitudinal direction between the atomizer 212 and the mouthpiece or mouth-engaging end 220 of the cartridge housing 200. According to certain features of the present invention, the second aerosol generating device 400 is typically porous or otherwise configured to allow air to pass through it. In certain cases, the second aerosol generating device 400 may comprise one or more aerosol generating elements 425, which may comprise at least one or a plurality of tablets or spherical particles or other appropriate elements or combinations thereof. In some cases, at least one or a plurality of pellets or spherical particles or other suitable elements or combinations thereof forming the aerosol forming element(s) 425 may be optionally coaxially surrounded by a generally tubular heat-conducting element and/or surrounded or otherwise enclosed by insulation (e.g., a non-woven mat or a layer of glass threads or fibers) or other suitable material (not shown).

It is believed that the overall configuration of the second aerosol generating device 400 inside the cartridge housing 200 of the aerosol delivery device/system 100 is typically cylindrical. Representative preferred spherical particles or other objects may be formed from a formulation comprising tobacco (e.g., particulate tobacco), tobacco components, and/or materials that are otherwise derived from tobacco (e.g., tobacco extracts, such as aqueous tobacco extracts, or nicotine derived from tobacco, including pharmaceutical grade nicotine). The spherical particles most preferably comprise flavors and a visible or invisible aerosol-forming material (e.g., glycerin or another material that produces a visible vapor resembling smoke). Thus, the components of the spherical particles are preferably configured to act as support components for volatile flavors, vapor-forming materials, moisture or other liquid(s), and/or aerosol-forming materials carried by them. According to certain features of the invention, the aerosol forming element(s) 425 may comprise or otherwise contain or be formed as, for example, marumarized spherical tobacco particles of various shapes and sizes, a monolith of bonded (e.g., sintered) spherical particles; a porous monolith (e.g., a spongy porous structure); a single porous structure; a honeycomb monolith or other porous geometric framework; a single fragment of porous material; spherical particles of extruded tobacco; spherical particles of a porous material containing tobacco extract (e.g., calcium carbonate, ceramic, glass, etc.); reconstituted tobacco trimmings; ground tobacco trimmings; extruded rods of various materials (including hollow cylinders and slotted rods) containing tobacco flavorings; shavings, fibres, flavour-releasing particles, flavour-containing (and flavour-releasing) polymers, granules, co-crystals, capsules, powders and/or microcapsules of various materials containing tobacco flavourings or other substances, in solid, liquid, gelatinous, colloidal, gaseous or other form; and combinations thereof or the result of processing thereof.

In some embodiments, the aerosol element(s) 425 may be implemented, at least in part, as a coating or film on the walls or lining of the housing body surrounding the aerosol-forming elements. For example, a film containing a microencapsulated flavoring agent may be applied to the walls or lining of the housing.

Generally, as used herein, the terms "tablets" and "spherical particles" mean spherical particles, tablets, or other discrete small units or pieces that may contain (in addition to elements otherwise disclosed herein), for example, carbonaceous pieces, extruded carbonaceous pieces cut into tablets, ceramic spherical particles, marumerized tobacco pieces, polymeric spherical particles, glass spherical particles, and the like, or combinations thereof. For example, the granules, tablets or spherical particles may be generally cylindrical or spherical extruded or pressed granules, tablets or spherical particles consisting of a moistened mixture or liquid solution of shredded tobacco leaf, fillers (e.g., granulated calcium carbonate), flavorings, visible aerosol forming materials and binders (e.g., carboxymethyl cellulose), which are formed, cut or extruded to the desired size and shape and then dried to maintain the desired configuration. However, such "tablets" or "spherical particles" may contain any suitable elements, or combinations of elements, that embody the preferred features disclosed herein. For example, some or all of the spherical particles or tablets may be heat-sensitive spherical capsules such that when included in the aerosol forming element and subjected to heat, their destruction or decomposition causes the release of glycerin, propylene glycol, water, saline solution, tobacco and/or nicotine flavorings or other substances or additives. In addition, the spherical particles may comprise ceramic or absorbent clay or silica or activated carbon for retaining and releasing the aerosol form. In addition, according to certain aspects of the invention, the spherical particles/tablets may comprise a heat-conducting material such as, for example, heat-conducting graphite, heat-conducting ceramic, metal, tobacco poured onto foil, metal or other suitable material impregnated with suitable aerosol-generating substances such as glycerin and flavoring(s), or a suitable cast sheet material that is suitably formed into the desired spherical particles/tablets.

In one particular example, the pellet/tablet particles (particles) may consist, by weight, of from about 15% to about 60% finely ground tobacco particles (e.g., a blend of Oriental, Burley, and flue-cured tobacco, substantially all Oriental, substantially all Burley, or substantially all flue-cured tobacco), from about 15% to about 60% finely ground calcium carbonate particles (or finely ground clay or ceramic particles), from about 10% to about 50% glycerin (and, if desired, a minor amount of flavorings), from about 0.25% to about 15% binder (preferably carboxymethyl cellulose, guar gum, potassium, or ammonium alginate), and from about 15% to about 50% water. In another example, the pellet/tablet particles (particles) may be comprised of about 30% finely ground tobacco particles (e.g., a blend of Oriental, Burley, and flue-cured tobacco, substantially all Oriental, substantially all Burley, or substantially all flue-cured tobacco), about 30% finely ground calcium carbonate particles (or finely ground clay or ceramic particles), about 15% glycerin (and, if desired, a minor amount of flavorings), about 1% binder (preferably carboxymethyl cellulose, guar gum, potassium, or ammonium alginate), and about 25% water. In such examples, the particles may be compressed to retain the glycerin and, after compression, may form a porous matrix that facilitates movement of the aerosol-producing components to maintain efficient aerosol formation. The manner in which the aerosol-forming material contacts the substrate material may vary. The aerosol-forming material may be applied to the formed material, may be included in processed materials during the manufacture of these materials, or may be endogenous to the material. The aerosol-forming material, such as glycerin, may be dissolved or dispersed in an aqueous liquid or other suitable solvent or carrier liquid and sprayed onto the substrate material. See, for example, U.S. Patent Application Publication Nos. 2005/0066986 (Nestor et al.) and 2012/0067360 (Conner et al.); the disclosures of which are incorporated herein by reference. Calcium carbonate or other inorganic filler assists in creating pores within the particles and may also function to absorb heat, which in some cases may limit or otherwise prevent combustion of the aerosol forming components, as well as aid and assist in aerosol formation. See also, for example, the types of materials disclosed in U.S. Patent No. 5,105,831 (Banerjee et al.) and U.S. Patent Application Publication Nos. 2004/0173229 (Crooks et al.); 2011/0271971 (Conner et al.); and 2012/0042885 (Stone et al.); the contents of which are incorporated herein by reference in their entirety.

In some embodiments, the spherical particles/tablets are divided pieces of extruded material containing a particulate material that serves as a support for flavors and/or aerosol-forming materials, such as tobacco (cut tobacco material) or a filler material (e.g., rice flour or other grain-based material and/or calcium carbonate), one or more binders (e.g., carboxymethyl cellulose), one or more flavors (e.g., menthol), and one or more aerosol-forming materials (e.g., glycerin). Optionally, the spherical particles/tablets can include one or more organic acids (e.g., levulinic or lactic) and/or one or more sweeteners (sugar or sugar substitute). The aforementioned materials can be mixed, pressed, and divided into portions of a desired size. Optionally, the mixed materials can also be marumerized.

In one embodiment, the aerosol forming elements 425, such as in the form of spherical particles or tablets, can be treated with smoke to impart a smoke flavor or aroma. For example, the spherical particles or tablets can be prepared and then exposed to smoke from a combustion source, such as a wood combustion source (e.g., wood selected from hickory, maple, oak, apple, cherry, or mesquite). The spherical particles or tablets can be treated with smoke for a time sufficient to acquire a desired smoky flavor or aroma, with an exemplary range of time values being from about 5 to about 45 minutes. The manner in which the pellets or tablets are contacted with the smoke can vary, with one example including heating the chips in a container until smoke is generated (e.g., heating the chips to a temperature of approximately 350-400°F) and placing the pellets or tablets to be treated with the smoke generated by the chips within a closed environment.

The composition of the aerosolizable composition for the first aerosol generating device and the composition of the aerosol generating elements for the second aerosol generating device are preferably selected so that they complement each other to form the desired perception process. For example, in certain embodiments of the present invention, the nicotine content of the aerosolizable composition and the aerosol generating elements is selected such that either or both of the aerosolizable composition and the aerosol generating elements may contain nicotine or nicotine compounds or may be considered to be substantially or completely free of nicotine or nicotine compounds. In other words, all of the nicotine content may be within the aerosol generating elements, or all of the nicotine content may be in the aerosolizable composition, or both compositions may include nicotine in a particular form.

According to certain features of the invention, where the aerosol forming elements 425 are, for example, spherical particles or tablets cast or extruded from the various types of materials mentioned above (i.e., a graphite spherical particle containing tobacco infusion and glycerin), wetted or otherwise treated before drying, they can be rolled, for example, between adjacent rollers to smooth the shape of the respective spherical particles/tablets. In some cases, the various types of materials mentioned above can be extruded in the form of filiform fibers, and these fibers can be collected to form a cylindrical rod or other material of a suitable shape (i.e., suitable in size to the spherical particles/tablets used to otherwise form the aerosol forming segment) for use in the second aerosol forming device 400. After drying, the smoothed spherical particles/tablets may then be milled or otherwise processed to form, for example, fibers, flakes, or other filler configurations that are flat or include a flat segment that inhibits or prevents rolling. Any random configurations resulting from the milling process may be sufficient. In such cases, the smoothed and milled spherical particles/tablets may then be included in the aerosol forming element(s) 425, and their irregular or random configurations may support, for example, a plurality of intermediate air spaces throughout the aerosol forming element(s) 425, wherein the intermediate air spaces may, in turn, support heat exchange with individual objects within the aerosol forming element(s) 425. Thus, heating the air in the interstitial spaces within the second aerosol forming device 400 may expose a greater portion of the aerosol forming element(s) 425 to heat from the heating element 240 and thus result in increased or otherwise improved heating of the aerosol forming element(s) 425. In other cases, the heat and the primary aerosol (i.e., the combination thereof) generated by the heating element 240/atomizer 212 are directed through a porous matrix formed by the aerosol forming element(s) 425, wherein the heated vapors passing through and heating the porous aerosol forming element(s) 425 support, for example, the elution (i.e., the extraction of liquid, fluid, or particles; distillation with water vapor; etc.) of an enhancing agent (i.e., a flavoring agent or other additive) from the aerosol forming element(s) into the primary aerosol, or otherwise support the enhancing agent being captured by, transferred to, reacting with, or otherwise interacting with the primary aerosol. The interaction between the enhancing substance and the primary aerosol can, for example, change or transform the primary aerosol, mix the enhancing substance with the primary aerosol to form an enhanced aerosol or aerosol mixture, or facilitate a reaction that forms a diverse aerosol. In such cases, the increased pore space within the aerosol forming element(s) 425 can support this interaction process through the second aerosol forming device 400.

According to certain aspects of the invention, the spherical particles/tablets may be formed from a tobacco material cast on a foil/paper laminate. More specifically, the tobacco material may be, for example, a liquid solution comprising reconstituted tobacco, glycerin, and a binder. Such a tobacco material is described, for example, in U.S. Patent No. 5,101,839 (Jacob et al.) and U.S. Patent Application No. 2010/0186757 (Crooks et al.), the contents of which are incorporated herein by reference. In addition, the liquid solution may comprise a granular inorganic material (i.e., calcium carbonate). The liquid solution is cast onto a foil/paper laminate, such as that described, for example, in U.S. Patent No. 8,678,013 (Crooks et al.) and U.S. Patent No. 7,647,932 (Cantrell et al.), the contents of which are also incorporated herein by reference, and the assembled cast sheet article is then dried, for example, by applying heat (e.g., hot air, microwave drying, etc.). The paper may have, for example, a certain porosity or texture to promote intimate contact and interaction with the liquid solution, such as in direct contact between the liquid solution and the foil. However, the exemplary feature presented herein does not preclude casting the tobacco material (i.e., the liquid solution) directly onto a metal foil or other suitable thin film heat conductor. After casting onto the laminate, the dried cast sheet (i.e., the foil/paper/tobacco material) may be shredded, cut into pieces, or otherwise divided into a plurality of cast sheet portion elements, each such element preferably comprising a portion of the tobacco material (i.e., the substrate) intimately associated with a portion of the paper element, which in turn intimately associates with a portion of the foil element in the foil/paper laminate. The plurality of cast sheet portion elements may then be included in an aerosol forming element(s) 425, forming a second aerosol forming device 400.

It will be appreciated by those skilled in the art that, in some circumstances, the cast sheet portion elements included in the aerosol forming element(s) 425 may act in concert to facilitate improved heat transfer to the tobacco material forming part of these cast sheet portion elements or otherwise to adjacent elements. In more detail, in some cases, heat transfer from the heating element 240 to the tobacco material included in the aerosol forming element(s) 425 may be limited along any immediate interface therebetween, with the heat-conducting tape forming an additional means for heat conduction from the heating element 240 to heat the external elements included in the aerosol forming element(s) 425 and any aerosol forming element(s) in contact therewith. In embodiments comprising partial cast sheet elements included in the aerosol forming element(s) 425, the heat-conducting portions of the foil element associated with the partial cast sheet elements may form, for example, a plurality of additional heat-conducting paths. Thus, the partial cast sheet elements used as all or a portion of the aerosol forming element(s) 425 may provide additional heat-conducting elements interspersed throughout the aerosol forming element(s) 425 within the second aerosol forming device 400 to thereby enhance or otherwise improve heat transfer toward and between the aerosol forming elements. In implementing such a feature, it may be additionally advantageous to mill or process the substrate material, such as in a substrate material of a cast tobacco sheet forming a substrate contained within certain types of cigarettes marketed under the Eclipse trademark by R. J. Reynolds Tobacco Company, as disclosed, for example, in U.S. Patent No. 5,469,871 (Barnes et al.).

The tablets or other elements may have smooth, regular external shapes (e.g., a sphere, a cylinder, oval surfaces, etc.) and/or they may have irregular external shapes (e.g., crushed parts, flakes, etc.). The aerosol generating element(s) 425, discretely or collectively, may have a generally cylindrical shape within the second aerosol generating device 400, and may in some cases include a plurality of from about 800 to about 1200 generally spherical, ball-shaped particles, each of which has an average or nominal diameter of from about 0.05 mm to about 4 mm (i.e., about 1 ^mm3 by volume, in one example), wherein the ball-shaped particles/tablets collectively weigh from about 450 mg to about 750 mg (e.g., 600 mg ± 25% in one example).

In one method of preparing substantially spherical particles of a ball-shaped form or tablets of aerosol forming elements may be formed by pre-mixing together the desired composition, followed by shaking the composition to form an extrudate. The extrudate is then processed in a spheronizer (such as those manufactured by Caleva Process Solutions Ltd. and LCI Corporation) to produce spheroids of various sizes, which may be processed through a series of screens to obtain a desired range of sizes, such as those noted above.

The aerosol forming elements can be selected so as to have a relatively uniform average diameter, or a range of sizes of aerosol forming elements can be included in the second device 400 for forming an aerosol. When using different size ranges in the same device, the elements of different sizes can be arranged in the form of a difference in values or in the form of layers inside the second device 400 for forming an aerosol, or the elements of different sizes can be randomly mixed inside the device 400 for forming an aerosol. Although this is not associated with any particular theory of operation, but the use of aerosol forming elements of different sizes in the same device 400 for forming an aerosol can provide advantageous changes in the pressure drop in the device and/or provide advantageous sensory characteristics based on different evaporation rates provided by the elements of different sizes.

In a preferred embodiment of the present invention, a sufficient number of spherical particles are loaded into the second aerosol forming device 400 to provide at least about 95 percent of the maximum loading when using spherical particles and/or other suitable elements. It is advantageous to avoid large open pockets within the aerosol forming device 400 that could allow air to pass through the aerosol forming device while substantially bypassing interaction with the aerosol forming elements 425.

In some cases, a plurality of forms of the aerosol forming element(s) 425 may be selected (e.g., the aerosol forming element(s) having different compositions) and each selected form of the aerosol forming elements is subsequently included in the second aerosol forming device 400. In other cases, the selected forms of the aerosol forming elements may be combined, prior to inclusion in the second aerosol forming device 400, to form a mixture of the aerosol forming elements, and this mixture is subsequently included in the second aerosol forming device 400.

The atomizer or first aerosol generating device 212 and the second aerosol generating device 400 may be physically separated from each other and/or comprise discrete units or segments within the cartridge housing 200. In some cases, as shown, these segments may be installed/arranged such that the downstream end (towards the mouthpiece or toward the mouth-engaging end 220 of the cartridge housing 200) of the atomizer or first aerosol generating device 212 is located near the upstream end of the second aerosol generating segment 400 (i.e., with the rear surface of the aerosol generating element(s) 425). Thus, the atomizer or the first aerosol forming device 212 and the second aerosol forming segment 400 may be axially symmetrically oriented in a sequential arrangement "end to end", and in some cases adjacent to each other or with an abutment against each other. For example, in some cases, although they are physically discrete and mounted downstream of the atomizer or the first aerosol forming device 212, it may be desirable for the aerosol forming element(s) 425 of the second aerosol forming device 400 to be in physical contact with the heating element 240 in the downstream end of the atomizer or the first aerosol forming device 212. Alternatively, these segments 212, 400 may be slightly spaced from each other such that their respective ends or components 240, 425 do not necessarily physically contact the other (i.e., to prevent scorching). Those skilled in the art will appreciate that in some embodiments of the invention, the second aerosol generating device 400 may comprise more than one section or portion of the aerosol generating element(s) 425.

In some cases, an additional segment, a spacer element, or a separator element (otherwise referred to herein as a "first separator element") acting as a spacer element or a screen (see, for example, element 450 in Fig. 3), may be mounted generally perpendicular to the longitudinal axis of the cartridge housing 200, and the first separator element 450 may provide a physical separation of these two segments 212, 400, while in some cases maintaining a thermally conductive relationship between them. The first separator element 450 in some cases may not be thermally conductive and, in other cases, the first separator element 450 may not be electrically conductive. Thus, the first separating element 450 may, but does not necessarily, be heat-conducting and/or arranged so as to conduct heat from the heating element 240 of the atomizer/first aerosol forming device 212 to the second aerosol forming device 400, and the aerosol forming element(s) 425 may be sensitive to heat and/or the accompanying primary aerosol to form a secondary aerosol. In addition, in some cases, the first separating element 450 may be air-permeable or otherwise configured to allow air flow to pass through it, so that the primary aerosol generated by the atomizer/first aerosol forming device 400 can pass through it in a downstream direction. The first separating element 450 may thus be configured to and/or arranged to support the aerosol forming element(s) 425 within the second aerosol forming device 400 and separately from the atomizer/first aerosol forming device 212. In other cases, the first separating element 450 may be configured as a spacer (i.e., extending longitudinally along the cartridge body 200 to determine the thickness) to separate the aerosol forming element(s) 425 from the heating element 240 of the atomizer/first aerosol forming device 212, for example, to minimize or prevent scorching or burning of the aerosol forming element(s) 4125 (i.e., the spherical particles) by the heat from the heating element 240. In some cases, the first separating element 450 may also be configured as an insulator (i.e., electrically non-conductive) to prevent short-circuiting of the heating element 240 in the event of contact between them.

Typically, the first separator element 450 is generally cylindrical or disc-shaped in shape and in a single-piece structure, and is air-permeable to allow drawn air to pass through it. The first separator element 450 may be thermally conductive in nature, so that the heat generated by the heating element 240 can be easily transferred to the second aerosol forming device 400. The length (thickness) of the first separator element 450 may vary, and typically ranges from values of less than about 1 mm to about 10 mm. In some cases, the relative longitudinal placement of the first separator element 450 within the outer shell 216 leaves a gap between the heating element 240 and the interface of the first separator element 450 and the aerosol forming element(s) 425, which ranges from about 1 mm to about 20 mm (i.e., 7 mm in one example). Typically, the first separating 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.) cell or screen, a highly heat-resistant plastic, etc. In some cases, the first separating element 450 may, for example, comprise longitudinally elongated air ducts formed during design/production, drilled through it, or otherwise cast, extruded, printed (i.e., representing a three-dimensional printed element obtained by means of a three-dimensional printer), or made in the form of a spacer element during its production. If desired, the first separating element 450 may comprise catalytic materials, for example, materials comprising ions or oxides of cerium or copper or oxides and/or salts of ions of cerium and copper. See, for example, U.S. Patent Nos. 8,469,035 and 8,617,263 (Banerjee et al.) and U.S. Patent Application Publication No. 2007/0215168 (Banerjee et al.), the entire contents of which are incorporated herein by reference.

In cases of surrounding the aerosol forming element(s) 425 with an insulation layer, a layer of heat-conducting material (for example, a layer or tape consisting of a metal foil) can be provided between them (not shown). Thus, the representative aerosol forming element(s) 425 comprises a plurality of tablets and/or other corresponding elements, which can be surrounded along its length by a layer of a strip of metal foil. The representative metal foil is, for example, an aluminum foil with a thickness of from about 0.01 mm to about 0.05 mm. In a preferred embodiment of the present invention, the metal foil is extended along the entire length of the outer coaxial surface of the aerosol forming element(s) 425; and it is preferable that the metal foil is extended over (i.e., at least partially overlaps) the first separating element 450. The heat-conducting material can be provided by means other than using a metal foil. For example, the layer of metal foil can be replaced by a metal mesh or a screen. Alternatively, the metal foil may be replaced by a heat-conducting fabric, such as a layer or sheet of graphite fibers or heat-conducting ceramic fibers. Alternatively, the heat-conducting material may be provided by applying heat-conducting ink, such as an ink or paint coating that contains metal particles, graphite fibers, particles of heat-conducting ceramic materials, etc.

Fig. 7 shows an example of another embodiment of a second device 400 for generating an aerosol, located inside the outer shell or tubular element 216 (downstream of the first device 212 for generating an aerosol, which is not shown). As shown, the elements 425 for generating an aerosol are located between the separating elements 450 and 475, which are designed to hold the elements 425 for generating an aerosol in place and to allow air flow to pass through them. As noted earlier, the separating elements 450 and 475 can be made porous (for example, in the form of honeycomb screens or perforated metal plates) with pore sizes selected to hold the elements 425 for generating an aerosol inside the second device 400 for generating an aerosol.

As shown, the second device 400 for generating an aerosol can further comprise a separate housing 460 of the element for generating an aerosol in the form of, for example, a tubular housing with an open end facing the mouthpiece 220, which, as shown, can be engaged with the open end of the tubular housing and can be attached to it by means of a press fit or other known means. The housing 460 can comprise an end 470 opposite the mouthpiece 220, which, as shown, can be perforated for passing an air flow through it. The housing 460 can be made of any suitable material, including metal (for example, stainless steel) or plastic. The separating elements 450 and 475 can be press fit or otherwise engaged with the housing 460, and the separating element 475 closest to the mouthpiece 220 can be attached to the mouthpiece if necessary. In certain embodiments of the present invention, the separating elements 450 and 475 are introduced into the housing 460 during a pressing process that forms the housing. The design of Fig. 7 is particularly well suited to embodiments of the invention, wherein the second aerosol generating device 400 is intended to be permanently attached to the remainder of the housing 200 of the cartridge, rather than being in the form of a removable or disposable device.

Alternatively, in embodiments of the present invention where the second aerosol generating device 400 is adapted to be removed from the cartridge housing 200 as a separate unit, the structure of Fig. 8 is preferred. 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 that is connected (e.g., by corrugation or other means) to a first connecting device 540. The housing body 520 and the first connecting device 540 together define a cavity for the aerosol generating elements 425. As in the embodiment of Fig. 7, the aerosol generating elements 425 are located between spacers 450 and 475 that are designed to hold the aerosol generating elements 425 in place and allow air flow through them. Similar to the embodiment of Fig. 7 separating elements 450 and 475 can be press-fitted or otherwise engaged with the surrounding parts of the first connecting device 540 or the housing body 520, respectively, and can be introduced into these surrounding parts during the pressing process. The separating element 475 located downstream is also attached to the mouthpiece 220 if necessary.

The first connecting device 540 of the second aerosol generating device 400 is adapted to engage with the second connecting device 560, which is attached (for example, by means of a press fit or other means) to the outer housing or tubular element 216, containing the first aerosol generating device 212 (not shown). The second connecting device 560 has an end facing the first connecting device 540, which allows the user to removably attach the second aerosol generating device 400 to the cartridge housing 200, for example, by means of a threaded engagement or other connecting means. As shown, the second connecting device 560 is made porous to allow the air flow from the first aerosol generating device 212 to enter the second aerosol generating device 400. The second aerosol generating device 400 of this embodiment is jointly engaged with the mouthpiece 220 in a manner similar to Fig. 7.

According to certain features of the invention, another element of the spacer or another separator element (otherwise referred to herein as a "second separator element") acting as a spacer element or a shield (see, for example, element 475 in Fig. 3) can be mounted generally perpendicular to the longitudinal axis of the cartridge housing 200, and the second separator element 475 can provide for physical separation of the second aerosol generating device 400 from the mouthpiece or the mouth-cooperating end 220 of the cartridge housing 200. Thus, the second separator element 475 can, but does not have to, be thermally conductive and/or arranged to conduct heat from the second aerosol generating device 400 and through the mouthpiece or through the mouth-cooperating end 220 of the cartridge housing 200. However, the second separating element 475 may be configured to be breathable or otherwise configured to allow air flow through it, so that the primary aerosol generated by the atomizer/first aerosol generating device 212 and/or the secondary aerosol generated by the second aerosol generating device 400 may pass through them in a downstream direction and through the mouthpiece or through the mouth-cooperating end 220 of the cartridge housing 200. Thus, the second separating element 475 may also be configured to and/or arranged to support the aerosol generating element(s) 425 within the second aerosol generating device 400, without losing any aerosol generating element(s) through the mouthpiece or the mouth-cooperating end 220 of the cartridge housing 200.

According to certain features of the invention, as an alternative to discrete first and second separating elements 450, 475, which are formed in addition to the aerosol forming element(s) 425, the second aerosol forming device 400 may comprise a cartridge 500 (see, for example, Fig. 4), which has an elongated tubular body 525 and opposing end elements 550, 575, wherein each of the end elements 550, 575 can be formed heat-conducting and/or air-permeable in the same manner as the first and second separating elements 450, 475. Thus, the elongated tubular body 525 may be further formed with the possibility of receiving the aerosol forming element(s) 425 and entering into interaction with the opposing end elements 550, 575 to contain the aerosol forming element(s) 425 within itself. The assembled cartridge 500 may thus be configured to be formed as a block (forming the second aerosol generating device 400) by the outer housing or tubular element 216 of the cartridge housing 200.

Fig. 9 shows an embodiment of the invention, in which the housing body 520 comprises a plurality of stackable containers 580a, 580b, 580c, each container housing aerosol generating elements 425. Each container, for example 580a, may include different aerosol generating elements 425, providing a different sensory experience. Thus, the consumer can stack a plurality of containers of different types in any desired order in order to change the sensory experience of the aerosol delivery system 100. Each individual container, 580a, 580b, 580c, may have a similar design, such as, for example, the general design shown in Fig. 4, such that the aerosol generating elements 425 are located in a porous wall of the container, which allows gaseous flow to pass through them. The number of stackable containers used may vary and is not limited to the illustrated embodiment of three containers. An approximate range for the total number of stackable containers is from 2 to about 8 (e.g. 2, 3, 4, 5, 6, 7, or 8 containers arranged in a stackable form).

Fig. 10 shows an embodiment in which the stackable container 580a, as shown in Fig. 9, has interior walls that divide the interior compartment into a plurality of wedge-shaped compartments so that various aerosol forming 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 divided compartment does not necessarily have to be wedge-shaped. Additional non-limiting examples of compartment shapes include concentric circles, triangular or rectangular compartments. The number and size of the divided compartments can vary and is not limited to the illustrated embodiment of four compartments. An exemplary range for the total number of compartments is from 2 to about 6 (e.g., 2, 3, 4, 5 or 6 compartments). The use of internal walls to divide the compartment into several compartments containing aerosol forming elements 425 is not limited to the stackable embodiment of the container of Fig. 9. For example, the single compartment shown in Fig. 8 can also be divided in this manner.

In use, the mouthpiece or the mouth-engaging end 220 of the cartridge housing 200 of the aerosol delivery system 100 is inserted into the user's mouth. The atomizer/first aerosol-generating device 212 is then activated, for example, by a puff (e.g., suction) performed by the user on the mouthpiece or on the mouth-engaging end 220 of the cartridge housing 200. The heating element 240 and the liquid transfer element 238 are configured to be in a heat-exchange relationship. In this way, the heat generated by the heating element 240 heats the composition to be aerosolized, carried by the liquid transfer element 238, to generate a primary aerosol. The heat generated by the heating element 240 and the primary aerosol are then brought into contact with the second aerosol generating device 400 and through it (i.e., through the aerosol generating element(s) 425) to the inhalation opening formed by the mouthpiece or mouth-engaging end 220. In some cases, the heat from the heating element 240 may interact with the aerosol generating element(s) 425 to generate a secondary aerosol. The secondary aerosol may interact or mix with the primary aerosol to form a tertiary aerosol, where the tertiary aerosol is an aerosol delivered to the user through the mouthpiece 220 in response to a draw applied thereto by the user. In some cases, the interaction between the heat and/or the primary aerosol and the aerosol forming element(s) 425 may cause the enhancing substance to enter into the primary aerosol to form an enhanced aerosol. For example, a medicament adsorbed on the aerosol forming element(s) 425 may react with the primary aerosol and/or heat, or otherwise be deadsorbed from the aerosol forming element(s) 425 by the primary aerosol and/or heat, and combine with the primary aerosol to form an enhanced aerosol. In other cases, the aerosol forming element(s) 425 may be configured such that the interaction of the primary aerosol with it causes heat to be drawn from the primary aerosol (i.e., cooling of the primary aerosol occurs). When implemented accordingly by the user, at least the primary aerosol generated by the atomizer 212 and the aerosol that has been acted upon by the second aerosol generating device 400 are generated and delivered to the user's mouth.

The components of the second aerosol generating device 400 and/or the aerosol generating element(s) 425 housed therein may be different. Typically, the second aerosol generating device 400 and/or the aerosol generating element(s) 425 housed therein may comprise components that may be vaporized, converted into an aerosol or entrained in air drawn through the aerosol supply system 100 during use. Most preferably, these components, alone or together with the primary aerosol generated by the first aerosol generating device 212, provide sensory and organoleptic effects such as odor, aroma, taste impression, sensations associated with a visible aerosol, etc. Examples of components of the first and/or second aerosol generating devices 212, 400 that are drawn into the user's mouth during a puff include water (e.g., in the form of water vapor), visible or non-visible aerosol forming materials (e.g., glycerin), various volatile aromatic substances (e.g., vanillin and menthol), volatile components of tobacco (e.g., nicotine), etc.

A preferred aerosol forming material forms an aerosol (either visible or not) when sufficient heat is applied thereto or otherwise by exposure to aerosol forming conditions when using the components of the aerosol delivery system. A preferred aerosol forming material produces a visible aerosol that is considered to be "smoke-like". A preferred aerosol forming material is chemically simple compared to the chemical nature of smoke produced by burning tobacco. A preferred visible aerosol forming material is a polyol, and exemplary preferred aerosol forming materials include glycerin, propylene glycol, and mixtures thereof. If desired, the aerosol forming materials can be combined with other liquid materials, such as water. For example, aerosol forming material formulations can comprise mixtures of glycerin and water or mixtures of propylene glycol and water. See, for example, the various aerosol forming materials referenced in U.S. Patent No. 8,678,013 (Crooks et al.), the contents of which are incorporated herein by reference.

The aerosol-forming materials are carried or supported by substrate materials to maintain the aerosol materials within a desired region of the smoking article. Exemplary substrate materials and exemplary formulations containing the aerosol-forming materials are set forth in U.S. Patent No. 4,793,365 (Sensabaugh et al.); U.S. Patent No. 4,893,639 (White); U.S. Patent No. 5,099,861 (Clearman et al.); U.S. Patent No. 5,101,839 (Jakob et al.); U.S. Patent No. 5,105,836 (Gentry et al.); U.S. Patent No. 5,159,942 (Brinkley et al.); U.S. Patent No. 5,203,355 (Clearman et al.); U.S. Patent No. 5,271,419 (Arzonico et al.); U.S. Patent No. 5,327,917 (Lekwauwa et al.); U.S. Patent No. 5,396,911 (Casey, III, et al.); U.S. Patent No. 5,533,530 (Young et al.); U.S. Patent No. 5,588,446 (Clearman); U.S. Patent No. 5,598,868 (Jakob et al.); and U.S. Patent No. 5,715,844 (Young et al.); and U.S. Published Patent Application No. 2005/0066986 (Nestor et al.); the contents of which are incorporated herein by reference. See also " Chemical and Biological Studies of New Prototype Cigarettes That Heat Rather Than Burn Tobacco ," R. J. Reynolds Tobacco Company Monograph (1988). The substrate materials used as examples were incorporated inside certain types of cigarettes commercially sold under the Premier and Eclipse trade names by R. J. Reynolds Tobacco Company.

In some cases, the aerosol delivery system described with reference to Fig. 1 can be used in a similar manner as commercially sold electronic cigarettes. As a result, when smoking, the preferred aerosol delivery system 100 of the types disclosed herein is capable of producing a visible primary aerosol that arises primarily from the vaporized components of the first and second aerosol generating devices 212, 400, and the visible aerosol in many respects resembles the primary tobacco smoke of a traditional type of cigarette in which chopped tobacco is burned.

In another example, substantially the entire cartridge housing 200 may be formed from one or more carbonaceous materials (see, for example, Fig. 5), which may provide advantages over other cartridge housing configurations disclosed herein in terms of biodegradability and the absence of wires. In this regard, the heating element may comprise carbonaceous foam, the reservoir may comprise carbonized fabric, and graphite may be used to form an electrical connection with the battery and the controller. Examples of a carbon-based cartridge housing are provided in US Published Patent Application Nos. 2015/0059780 (Davis et al.) or 2013/0255702 (Griffith et al.), the contents of which are incorporated herein by reference in their entirety. In some cases, the inclusion of a second aerosol generating device disclosed herein may also be applicable to such a carbon-based cartridge housing. For example, as shown in Fig. 6A and 6B, a portion 625 (see, for example, Fig. 6A) of a cartridge element 600 located toward a mouthpiece of a cartridge housing may be formed or otherwise modified (see, for example, Fig. 6B) to provide one or more aerosol-forming element(s) 425 of the types disclosed herein. Alternatively, a pre-assembled cartridge containing such aerosol-forming element(s) 425 may be implemented, or the cartridge element 600 and/or the outer shell receiving the cartridge element 600 may be configured to provide first and second separating elements having aerosol-forming elements therebetween, as otherwise disclosed herein.

Many modifications and other features of the present invention set forth herein will be apparent to those skilled in the art having the benefit of the information provided in the preceding descriptions and the accompanying drawings. For example, those skilled in the art will appreciate that embodiments not expressly set forth herein may be practiced without departing from the scope of the present invention, and that features described herein for various embodiments may be combined with each other and/or with currently known or future technologies without departing from the scope of the claims set forth herein. It is therefore to be understood that the present invention is not to be limited to the specific embodiments disclosed and that equivalents, modifications, and other embodiments are intended to be included within the scope of the appended claims. Although certain terms are used herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims (18)

1. An aerosol delivery system comprising: a part in the form of a control body, comprising a first elongated tubular element having opposite ends, and a power source placed therein; and a part in the form of a cartridge body, comprising a second tubular element having opposite first and second ends, wherein the first end is engaged with one of the opposite ends of the part in the form of a control body, the part in the form of a cartridge body additionally comprises a first device for forming an aerosol, placed inside the second tubular element and configured to receive power from the power source after engagement between one of the opposite ends of the part in the form of a control body and the first end of the part in the form of a cartridge body, the second end of the part in the form of a cartridge body facing the end of the aerosol delivery system interacting with the mouth; and a second aerosol generating device located between the first aerosol generating device and the mouth-interacting end of the aerosol delivery system, wherein the second aerosol generating device is designed to be engaged with the part in the form of a cartridge housing and is designed with the possibility of being disengaged from it or is located inside the second tubular element of the part in the form of a cartridge housing; wherein the second aerosol generating device comprises an outer body of the housing and an inner compartment divided into a plurality of sub-compartments capable of containing a plurality of elements for generating an aerosol. 2. The aerosol delivery system of claim 1, wherein the second aerosol generating device further comprises a plurality of aerosol generating elements. 3. An aerosol delivery system according to claim 2, wherein the plurality of elements for forming the aerosol are made in the form of spherical particles or tablets. 4. An aerosol delivery system according to claim 3, wherein each spherical particle or tablet is in the form of an extruded material comprising a particulate material selected from tobacco material and filler, at least one aerosol-forming material and at least one binder material. 5. An aerosol delivery system according to any one of claims 1-4, further comprising a first separating element located within the second tubular element between the first aerosol forming device and the second aerosol forming device, wherein the first separating element is a heat-conducting or air-permeable element. 6. An aerosol delivery system according to claim 5, wherein the first separating element extends along a longitudinal axis between the opposite ends and has a thickness such that the first separating element forms a gap between the second aerosol forming device and the heating element of the first aerosol forming device. 7. An aerosol delivery system according to any one of claims 5, 6, further comprising a second separating element located between the second aerosol generating device and the mouth-interacting end, wherein the second separating element is a heat-conducting or air-permeable element. 8. An aerosol delivery system according to any one of claims 2 to 7, wherein the second aerosol forming device comprises a cartridge having an elongated tubular body and opposing end members, each of which is a heat-conducting or air-permeable element, wherein the elongated tubular body is configured with the additional possibility of receiving a plurality of elements for forming an aerosol and interacting with the opposing end members to contain therein a plurality of elements for forming an aerosol, the cartridge is configured to be received by the second tubular element. 9. An aerosol delivery system according to any one of claims 1 to 8, wherein the first aerosol generating device comprises a liquid reservoir located within the second tubular element and configured to receive a substance to be aerosolized used by the first aerosol generating device to generate a primary aerosol. 10. The aerosol delivery system of claim 9, wherein the substance to be aerosolized is one of the following: glycerin, propylene glycol, water, saline solution, nicotine, organic acids, or combinations thereof. 11. An aerosol delivery system according to any one of claims 1-10, in which the first aerosol generating device comprises a heating element configured to supply heat for generating a primary aerosol, and the second aerosol generating device comprises at least one aerosol generating element, wherein the at least one aerosol generating element is arranged to interact with said heat and the primary aerosol drawn therethrough in the direction of the mouth-engaging end in response to suction applied to the mouth-engaging end. 12. An aerosol delivery system according to any one of claims 2 to 11, wherein the aerosol forming elements comprise one or more components of tobacco in the form of particles, tobacco infusion and nicotine, wherein the nicotine is in the form of a free base, in a salt form, as a complex compound or a solvate. 13. An aerosol delivery system according to any one of claims 2 to 12, wherein the aerosol forming elements further comprise one or more flavoring agents. 14. The aerosol delivery system of claim 1, wherein the second aerosol generating device is located within the second tubular element of the cartridge body portion and comprises a plurality of elements for generating an aerosol in the form of spherical particles or tablets held in place by a first air-permeable separator element located within the second tubular element between the first aerosol generating device and the second aerosol generating device, and a second separator element located between the second aerosol generating device and the mouth-engaging end. 15. The aerosol delivery system of claim 1, wherein the second aerosol generating device is engaged with the cartridge housing portion and is releasable therefrom and comprises a plurality of elements for generating an aerosol in the form of spherical particles or tablets held in place by a first air-permeable separating element located between the first aerosol generating device and the second aerosol generating device, and a second separating element located between the second aerosol generating device and the mouth-interacting end. 16. An aerosol delivery system according to any one of claims 1 to 15, wherein the second aerosol generating device comprises an outer housing body and a plurality of stackable, gas-permeable containers within the outer housing body, each container comprising a plurality of aerosol generating elements. 17. An aerosol delivery system according to any one of claims 1-15, wherein each of the sub-compartments comprises a plurality of different elements for forming an aerosol. 18. An aerosol delivery system according to any one of claims 3-17, wherein the spherical particles or tablets further comprise a substrate material selected from the group consisting of spherical glass particles, fibers, honeycomb structures, porous monoliths and spherical polymer particles.