RU2849495C1 - Aerosol delivery device with downstream flavour cartridge - Google Patents

Abstract

FIELD: smoking accessories.

SUBSTANCE: group of inventions relates to the tobacco industry, in particular to devices simulating the tobacco smoking process. Flavouring substance delivery device contains at least one flavouring substrate formed from the porous material and passing along the longitudinal axis between the first end and the opposite second end. Flavouring material is included in the flavouring substrate, the outer sleeve enclosing the outer perimeter of the at least said flavouring substrate, wherein the outer sleeve is impermeable for the flavouring material. Outer casing extends along the longitudinal axis between the far end including at least one hole, and the near end including at least one hole. Outer casing comprises outer wall defining chamber. At least one flavouring substrate is located inside the outer casing chamber so that the longitudinal axis of the said at least one substrate is parallel to the longitudinal axis of the outer casing. One of the near end and the far end of the outer casing is configured to engage with the mouth end of the smoking article. Cartridge for an aerosol delivery device comprises a cartridge casing having a mouthpiece end, an aerosol precursor composition arranged inside the casing, an atomizer configured to evaporate the aerosol precursor composition, and the disclosed flavour delivery device.

EFFECT: improved tightness of the device for delivery of a flavouring substance.

23 cl, 17 dwg

Description

AREA OF TECHNOLOGY

The present invention relates to flavor delivery devices capable of being combined with aerosol delivery devices. More specifically, such a flavor delivery device may comprise an elongated flavor substrate comprising at least one flavor material, wherein the flavor substrate is substantially surrounded by an outer sleeve and, in some cases, located substantially within the outer frame.

LEVEL OF TECHNOLOGY

Over the years, numerous smoking articles have been proposed as improvements or alternatives to tobacco-based smoking products. Typical alternatives have included devices that burn solid or liquid fuel to transfer heat to the tobacco, or that use a chemical reaction to provide such a heat source. Examples include the smoking articles described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference.

The goal of improving smoking articles or creating alternatives to them has typically been to provide the sensations associated with smoking a cigarette, cigar, or pipe without delivering significant amounts of incomplete combustion and pyrolysis products. To this end, a variety of smoking articles, aroma generators, and medicinal inhalers have been proposed that use electrical energy to vaporize or heat a volatile material or attempt to provide the sensations of smoking cigarettes, cigars, or pipes without significantly burning the tobacco. For example, more detailed information on various alternative smoking articles, aerosol delivery devices, and heat-generating sources disclosed in the prior art is provided in U.S. Patent No. 7,726,320 to Robinson et al. and U.S. Patent Application Publication No. 2013/0255702 to Griffith Jr. and 2014/0096781 by Sears et al., which are incorporated herein by reference. Further details on this matter are also provided, for example, in the description of various types of smoking articles, aerosol delivery devices, and electrically driven heat generating sources, which are referenced by trademark and trade information in U.S. Patent Application Publication No. 2015/0220232 by Bless et al., which is incorporated herein by reference. Additional types of smoking articles, aerosol delivery devices, and electrically driven heat generating sources, which are referenced by trademark and trade information, are set forth in U.S. Patent Application Publication No. 2015/0245659 by DePiano et al., which is also incorporated herein by reference in its entirety. Other representative cigarettes or smoking articles that have been described and, in some cases, made commercially available include those described in U.S. Patent No. 4,735,217 to Gerth et al.; U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al.; U.S. Patent No. 5,060,671 to Counts et al.; U.S. Patent No. 5,249,586 to Morgan et al.; U.S. Patent No. 5,388,594 to Counts et al.; U.S. Patent No. 5,666,977 to Higgins et al.; U.S. Patent No. 6,053,176 to Adams et al.; US Patent No. 6,164,287 by White; US Patent No. 6,196,218 by Voges; US Patent No. 6,810,883 by Felter et al.; US Patent No. 6,854,461 by Nichols; US Patent No. 7,832,410 by Hon. US Patent No. 7,513,253 by Kobayashi; US Patent No. 7,726,320 by Robinson et al.; US Patent No. 7,896,006 by Hamano; US Patent No. 6,772,756 by Shayan; publication of US patent application No. 2009/0095311 by Hon; U.S. Patent Application Publication Nos. 2006/0196518, 2009/0126745, and 2009/0188490 to Hon; U.S. Patent Application Publication No. 2009/0272379 to Thorens et al.; U.S. Patent Application Publication Nos. 2009/0260641 and 2009/0260642 to Monsees et al.; U.S. Patent Application Publication Nos. 2008/0149118 and 2010/0024834 to Oglesby et al.; U.S. Patent Application Publication No. 2010/0307518 to Wang; and WO 2010/091593 to Hon, which are incorporated herein by reference.

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

There remains a need in the art for additional means for adding flavoring to aerosols. Accordingly, it would be desirable to provide a flavor delivery device that can be easily integrated with the aerosol delivery device to add a flavoring substance or flavoring mixture to the resulting aerosol at the user's discretion.

DISCLOSURE OF THE ESSENCE OF THE INVENTION

In various embodiments, the present invention provides a flavor delivery device that can be included in or combined with an aerosol delivery device. The flavor delivery device may comprise at least one elongated flavor substrate that is designed to or configured to retain a flavor material that can be released therefrom to be drawn into the aerosol flow. Accordingly, the flavor delivery device is configured to be included in or attached to the aerosol delivery device, wherein the flavor delivery device is located downstream of a liquid reservoir in the aerosol delivery device that contains, for example, an e-liquid. A flavor delivery device containing another flavor material can either enhance the flavor effect of the e-liquid or generate a flavor substance when using an unflavored e-liquid.

In one aspect of the present invention, a flavor delivery device includes at least one elongated flavor substrate made of a porous material. The elongated flavor substrate extends along a longitudinal axis between two ends, where the first end is opposite the second end.

The extended flavor substrate includes flavor material.

The flavor delivery device also includes an outer sleeve surrounding the perimeter of said at least one elongated flavor substrate. The outer sleeve is impermeable to the flavor material. In some embodiments, the flavor delivery device may also be characterized by one or more of the following, which may be combined in any number or order.

One or more of the following conditions may be met: at least one elongated flavor substrate may be made in the form of one or more rods; at least one elongated flavor substrate may be made in the form of one or more tubes; at least one elongated flavor substrate may be made in the form of a single sheet with folds; at least one elongated flavor substrate may be made in the form of an assembled sheet; at least one elongated flavor substrate may be made in the form of a rolled sheet.

The porous material that forms at least one elongated flavor substrate may be a polymeric material.

The polymeric material forming at least one elongated flavor substrate may be selected from the group consisting of: polyethylene, polypropylene, polyester, polyester, polylactic acid (PLA), acetyl cellulose, nylon, ceramic, or any combination thereof.

The material forming the outer sleeve that surrounds at least one elongated flavor substrate may be selected from the group consisting of silicone, polyester, polyester, polypropylene, polylactic acid (PLA), nylon, or any combination thereof.

At least one elongated flavor substrate may be formed by a plurality of layers.

Each layer may also contain material with different densities.

Each layer may be configured to release flavoring material at different rates.

Each layer may also contain various flavoring materials.

The flavor delivery device may also comprise at least one elongated substrate that is made of a plurality of fibers.

A plurality of fibers may be sheath-core fibers.

The shell may be a porous material, while the core includes a flavoring material.

The flavor delivery device may also comprise an outer shell extending along the longitudinal axis between a distal end comprising at least one opening and a proximal end comprising at least one opening. The outer shell defines a chamber in which said at least one elongated flavor substrate is positioned within the chamber of the outer shell such that the longitudinal axis of said at least one elongated substrate is substantially parallel to the longitudinal axis of the outer shell.

The outer casing of the flavor delivery device may comprise one or more openings formed within the outer wall of the casing.

The extended flavor delivery device can be removable and replaceable.

The proximal end of the outer shell of the flavoring delivery device may be configured to interact with the mouthpiece end of the smoking device.

In another embodiment of the present disclosure, at least a portion of the flavoring material may be provided in a destructible capsule.

The flavor delivery device may include a plurality of capsules configured to be destructible.

The destructible capsules may include capsules of at least two substantially different sizes.

In another aspect of the present invention, a cartridge for an aerosol delivery device is provided. The cartridge may comprise, for example, a cartridge housing having a mouthpiece end; a reservoir containing an aerosol precursor composition; a heater configured to vaporize the aerosol precursor composition; and a flavor delivery device in accordance with other embodiments described herein, which is located downstream of the reservoir relative to the mouthpiece end of the cartridge.

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

Embodiment 1: A device for delivering a flavoring substance, comprising: at least one elongated flavoring substrate formed from a porous material and extending along a longitudinal axis between a first end and an opposite second end; a flavoring material included in the elongated flavoring substrate; and an outer sleeve, substantially surrounding the outer perimeter of said at least elongated flavoring substrate, wherein the outer sleeve is substantially impermeable to the flavoring material.

Embodiment 2: The flavoring substance delivery device according to embodiment 1, wherein one or more of the following conditions are met: at least one elongated flavoring substrate comprises one or more rods; at least one elongated flavoring substrate comprises one or more tubes; at least one elongated flavoring substrate is made in the form of a sheet with folds; at least one elongated flavoring substrate is made in the form of an assembled sheet; at least one elongated flavoring substrate is made in the form of a rolled sheet.

Embodiment 3: A device for delivering a flavoring substance according to any of embodiments 1 and 2, in which the porous material forming at least one elongated flavoring substrate is a polymeric material.

Embodiment 4: The flavor delivery device of any one of embodiments 1-3, wherein the polymeric material is selected from the group consisting of polyethylene, polypropylene, polyester, polyester, polylactic acid (PLA), acetyl cellulose, nylon, ceramic, or any combination thereof.

Embodiment 5: The flavor delivery device of any one of embodiments 1-4, wherein the outer sleeve is made of a material selected from the group consisting of silicone, polyester, polyester, polypropylene, polylactic acid (PLA), nylon, or any combination thereof.

Embodiment 6: A flavoring substance delivery device according to any of embodiments 1-5, wherein at least one elongated flavoring substrate is formed by a plurality of layers.

Embodiment 7: A flavor delivery device according to any of embodiments 1-6, wherein each layer comprises materials with different densities.

Embodiment 8: A flavor delivery device according to any one of embodiments 1-7, wherein each layer in the plurality of layers is configured to release the flavor material at different rates.

Embodiment 9: The flavor delivery device of any one of embodiments 1-8, wherein each layer in the plurality of layers contains a different flavor material.

Embodiment 10: A flavor delivery device according to any one of embodiments 1-9, wherein at least one elongated flavor substrate is formed from a plurality of fibers.

Embodiment 11: The flavor delivery device of any one of embodiments 1-10, wherein at least a portion of the plurality of fibers are sheath-core fibers.

Embodiment 12: A flavor delivery device according to any one of embodiments 1-11, wherein the shell is a porous material, and the flavor material is included in the core.

Embodiment 13: A flavor delivery device according to any one of embodiments 1-12 of the invention, further comprising an outer casing extending along a longitudinal axis between a distal end including at least one opening and a proximal end including at least one opening, wherein the outer casing comprises an outer wall defining a chamber, wherein said at least one elongated flavor substrate is located within the chamber of the outer casing such that the longitudinal axis of said at least one elongated substrate is substantially parallel to the longitudinal axis of the outer casing.

Embodiment 14: The flavor delivery device of any one of embodiments 1-13, wherein the outer casing comprises one or more openings formed within the outer wall of the casing.

Embodiment 15: A flavor delivery device according to any of embodiments 1-14, wherein the elongated flavor substrate is removable and replaceable.

Embodiment 16: A device for delivering a flavoring substance according to any of embodiments 1-15, in which the proximal end of the outer shell is configured to interact with the mouthpiece end of the smoking article.

Embodiment 17: A flavor delivery device according to any one of embodiments 1-16, wherein at least a portion of the flavor is provided in a destructible capsule.

Embodiment 18: A flavor delivery device according to any one of embodiments 1-17, wherein the device includes a plurality of capsules configured to be destructible.

Embodiment 19: The flavor delivery device of any one of embodiments 1-18, wherein the plurality of destructible capsules comprise capsules of at least two substantially different sizes.

Embodiment 20: A cartridge for an aerosol delivery device comprising: a cartridge housing having a mouthpiece end; a reservoir including an aerosol precursor composition; a heater configured to evaporate the aerosol precursor composition; and a flavor delivery device according to claim 1, positioned such that the evaporated aerosol precursor composition passes through it.

Embodiment 21: The cartridge of embodiment 20, also comprising a mouthpiece connected to the mouthpiece end of the cartridge housing.

Embodiment 22: A cartridge according to any of embodiments 20 and 21, wherein the mouthpiece comprises a device for delivering a flavoring substance.

Embodiment 23: A cartridge according to any of embodiments 20-22, in which the flavor delivery device is located above the mouthpiece.

Embodiment 24: A cartridge according to any of embodiments 20-23, in which the flavor delivery device is removable and replaceable.

Embodiment 25: A cartridge according to any one of embodiments 20-24, in which the flavor delivery device is releasably connected to the mouthpiece end of the cartridge and/or the mouthpiece by any one or more of a threaded connection, a magnetic connection, and a friction fit.

These and other features, aspects, and advantages of the present disclosure will become apparent upon reading the following detailed description and the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four, or more of the above embodiments, as well as combinations of any two, three, four, or more features or elements disclosed in this disclosure, regardless of whether such features or elements are intentionally combined in a particular embodiment described herein. The present disclosure is intended to be read as a whole, so that any individual features or elements of the disclosed invention in any of its various aspects and embodiments should be considered as combinable unless the context clearly dictates otherwise.

BRIEF DESCRIPTION OF DRAWINGS

To ensure understanding of the aspects of the invention further

References are made to accompanying drawings, which are not necessarily drawn to scale and in which similar

Elements have similar reference numbers. The drawings are provided for example purposes only and should not be construed as limiting this disclosure.

FIG. 1A shows a front view of an exemplary flavor delivery device.

FIG. 1B shows a front view of an exemplary flavor delivery device surrounded by an optional outer sleeve.

FIG. 2A is a perspective view of an exemplary embodiment of a flavor substrate having a substantially sheet-like shape according to the disclosure of the present invention;

FIG. 2B is a perspective view of an exemplary embodiment of a flavor substrate having a substantially rod-shaped form according to the disclosure of the present invention;

FIG. 2C is a perspective view of an exemplary embodiment of a flavor substrate having a substantially tubular shape according to the disclosure of the present invention;

FIG. 3A is a partial cross-sectional view of an exemplary embodiment of a flavor substrate that is at least partially surrounded by an outer film, wherein the flavor substrate is in the form of a pleated sheet;

FIG. 3B is a partial cross-sectional view of an exemplary embodiment of a flavor substrate that is at least partially surrounded by an outer film, wherein the flavor substrate is in the form of an assembled sheet;

FIG. 3C is a partial cross-sectional view of an exemplary embodiment of a flavor substrate that is at least partially surrounded by an outer film, wherein the flavor substrate is in the form of a rolled sheet;

FIG. 3D is a partial cross-sectional view of an exemplary embodiment of a flavor substrate that is at least partially surrounded by an outer film, wherein the flavor substrate is in the form of a plurality of rods;

FIG. 3E is a partial cross-sectional view of an exemplary embodiment of a flavor substrate that is at least partially surrounded by an outer film, wherein the flavor substrate is formed in the form of a plurality of tubes;

FIG. 3F is a partial cross-sectional view of an exemplary embodiment of a flavor substrate that is at least partially surrounded by an outer film, wherein the flavor substrate is formed as a combination of a tube and a plurality of rods;

FIG. 3G is a partial cross-sectional view of an exemplary embodiment of a flavor substrate that is at least partially surrounded by an outer film, wherein the flavor substrate is formed as a combination of a rolled sheet and a plurality of tubes;

FIG. 4A is a cross-sectional view of an exemplary multicomponent sheath/core fiber;

FIG. 4B is a cross-sectional view of an exemplary multicomponent "islands in the sea" fiber;

FIG. 5 is a front view of an exemplary flavor delivery device comprising an outer casing illustrating a body and a mouthpiece;

FIG. 6 shows an exploded view of an exemplary flavor substrate surrounded by an outer sleeve, wherein at least one destructible capsule containing a flavoring agent is optionally contained within the flavor substrate according to the disclosure of the present invention; and

FIG. 7 is a partial cross-sectional view of an aerosol delivery device incorporating a flavor delivery device according to the disclosure of the present invention.

IMPLEMENTATION OF THE INVENTION

The disclosure of the present invention is described in more detail below with reference to exemplary embodiments thereof. These exemplary embodiments are described in such a way that this disclosure thoroughly, completely, and fully conveys the scope of the invention to those skilled in the art. In fact, the present invention can be implemented in many different forms and should not be considered as limited to the embodiments given herein; rather, these embodiments are provided so that the present invention complies with applicable legal requirements. In this description and in the appended claims, a grammatical construction indicating that an element is given in the singular also implies the plural, unless the context of the invention clearly dictates otherwise.

The present disclosure provides descriptions of flavor delivery devices that are designed for, or configured to impart flavor to, a passing vapor or aerosol stream. The flavor delivery device is particularly suitable for integration with aerosol delivery devices. Thus, the flavor delivery device is designed for, or configured to impart flavor to, an aerosol generated in the aerosol delivery device. Aerosol delivery devices may utilize electrical energy to heat a material to form an inhalable substance; such devices may be compact enough to be considered "portable." An aerosol delivery device may provide some or all of the sensations (e.g., inhalation and exhalation rituals, types of flavors or aromas, organoleptic effects, physical sensation, rituals of use, visual stimuli such as those created by a visible aerosol, etc.) of smoking a cigarette, cigar, or pipe without actually burning any of the components of the article or device to any significant degree. Aerosol delivery devices may not generate smoke in the sense that the aerosol is the result of byproducts of combustion or pyrolysis of tobacco, but rather the article or device may generate vapors (including vapors in aerosols, which may be considered visible aerosols and may be described as smoke-like) resulting from the volatilization or evaporation of certain components of the article or device, although in other embodiments the aerosol may not be visible. In some embodiments, aerosol delivery devices may contain tobacco and/or components derived from tobacco. Thus, aerosol delivery devices can be characterized as an electronic smoking product, such as an e-cigarette.

Although the flavor delivery device is generally described herein with respect to embodiments associated with aerosol delivery devices such as so-called electronic cigarettes, it should be noted that the mechanisms, components, elements, and methods may be implemented in many different forms and associated with various products. For example, the description provided herein may be applied in conjunction with embodiments of traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heat-not-burn cigarettes, and corresponding packaging for any of the products disclosed herein. Furthermore, it should be noted that the description of the mechanisms, components, elements, and methods disclosed herein is presented with respect to embodiments of the invention related to aerosol delivery devices for exemplary purposes only and may be implemented and used in various other products and methods.

Aerosol delivery devices comprising a flavor delivery device in accordance with the present disclosure may also be characterized as vapor-generating articles or drug delivery devices. Thus, such articles or devices may be configured to provide one or more substances (e.g., flavors and/or pharmaceutically active ingredients) in an inhalable form or state. For example, the inhalable substances may be substantially in the form of a vapor (e.g., a substance that is in the gaseous phase at a temperature below its critical point). Alternatively, the inhalable substances may be in the form of an aerosol (e.g., a suspension of fine solid particles or liquid droplets in a gas). For simplicity, the term "aerosol" as used herein is intended to include vapors, gases, and aerosols of a form or type suitable for human inhalation, visible or invisible, and of a shape that can be considered smoke-like or not.

In use, aerosol delivery devices comprising a flavor delivery device according to the present disclosure can be used in various physical actions of a person using a traditional smoking article (e.g., a cigarette, cigar, or pipe, which is consumed by lighting and inhaling tobacco). For example, a user of the device according to the present invention can hold this article like a traditional smoking article, puffing on one end of said article to inhale the aerosol generated by this article, performing or performing puffs at selected intervals, and the like.

Thus, in one or more embodiments, the disclosure of the present invention may provide a flavor delivery device that may include at least a flavor substrate. The flavor material may be, for example, adsorbed and/or absorbed by the flavor substrate. In particular, the flavor material may be at least partially retained in the pores of the flavor substrate. The retention of the flavor material by the flavor substrate is preferably in a releasable relationship, such that the flavor material can be released from the flavor substrate to be captured in a passing aerosol stream. As will be further apparent from the description provided herein, the flavor delivery article may also comprise a flavor material that is configured to combine with the flavor substrate to be retained in this manner. Furthermore, the flavoring substrate, alone or in combination with the flavoring material, may be combined with the shell and/or outer casing. Additionally, the flavoring substrate may include one or more capsules that can be combined with it.

One exemplary embodiment of a flavor delivery device 50 is shown in FIGS. 1A and 1B. As shown in FIG. 1A, the flavor delivery device 50 may comprise at least one elongated flavor substrate 100, which is preferably formed from a porous material such that the flavor substrate may be designed for or configured to retain and release a flavor material. In FIG. 1B, at least one elongated flavor substrate 100 is shown, in which the outer perimeter is surrounded by an optional outer sleeve 125. Preferably, the outer sleeve 125 may be substantially impermeable to the flavor material retained by the flavor substrate 100. As shown in the drawing, the flavor substrate is substantially in the shape of a cylinder; However, it is understood that other configurations are also encompassed by the disclosure of the present invention, as will be more apparent from additional exemplary embodiments presented herein. The outer sleeve 125 may be present around at least a portion of the outer surface of the flavor substrate 100 and, thus, may surround at least a portion or substantially the entire outer perimeter of the substrate. Preferably, the flavor sleeve 125 is absent from opposite ends (101, 103) of the flavor substrate 100, so that the aerosol can pass from one end to the other end to capture the flavor material as it passes through the flavor substrate.

In some embodiments, the shown flavor substrate 100 is configured to extend along a longitudinal axis between a first end 101 and an opposite second end 103, and thus may have at least a longitudinal dimension or length L. The flavor substrate 100 may vary in shape, as further described below, and thus may include additional dimensions such as a thickness and/or width W. For example, the flavor substrate 100 may be configured to provide a substantially large surface area for the passage of flavor liquid from the flavor substrate to an aerosol stream passing along and/or through the flavor substrate. This may be achieved by providing the flavor substrate in a specific configuration and/or by providing a plurality of flavor substrates in combination. Such variations are evident with respect to the exemplary embodiments shown in FIGS. 2A-2C. As shown in FIG. 2A, the flavor substrate 100 extends along the longitudinal axis L between the first end 101 and the second end 103 and has a width W that extends along the axis perpendicular to the longitudinal axis L and a thickness X. Thus, the flavor substrate 100 can be substantially in the form of a sheet having a length (L) from about 0.2 cm to about 5 cm, from about 0.3 cm to about 3 cm, from about 0.4 cm to about 2.5 cm, or from about 0.5 cm to about 2 cm. Similarly, the flavor substrate can have a width (W) from about 10% of the length to about 4000% of the length, from about 20% of the length to about 2000% of the length, or from about 50% of the length to about 1000% of the length. The thickness (X) may be from about 5 microns to about 500 microns, from about 10 microns to about 400 microns, or from about 20 microns to about 300 microns. Thus, the flavor substrate 100, which is substantially in the form of a sheet, may be intended for or configured to be substantially flat. If necessary, the flavor substrate 100, which is made in the form of a flat sheet, may have an embossing and/or include a plurality of through perforations 104. The perforations may be substantially circular (see perforation 104a) or may be elongated (e.g., in the form of slits) - see perforation 104b.

As shown in FIG. 2B, the flavor substrate 100' again extends along the longitudinal axis L between the first end 101' and the second end 103' and is substantially in the form of a rod having a diameter d. The flavor substrate 101' in the form of a rod may have a length (L) from about 0.2 cm to about 5 cm, from about 0.3 cm to about 3 cm, from about 0.4 cm to about 2.5 cm, or from about 0.5 cm to about 2 cm, and may have a diameter from about 1 micron to about 2000 microns, from about 5 microns to about 1500 microns, or from about 10 microns to about 1000 microns.

As can be seen in FIG. 2C, the flavor substrate 100" again extends along the longitudinal axis L between the first end 101" and the second end 103" and is substantially in the form of a hollow tube having a diameter d. The flavor substrate 101" in the form of a tube may have a length (L) from about 0.2 cm to about 5 cm, from about 0.3 cm to about 3 cm, from about 0.4 cm to about 2.5 cm, or from about 0.5 cm to about 2 cm, and may have a diameter from about 0.5 mm to about 25 mm, from about 1 mm to about 20 mm, or from about 2 mm to about 15 mm. The tube may have a substantially continuous wall 105, which may vary in thickness X along the longitudinal axis of the flavor substrate 100". In some embodiments, the thickness X of the substantially continuous wall 105 is preferably substantially uniform along the longitudinal axis of the flavor substrate 100". The substantially continuous wall 105, for example, may have an average thickness X of from about 0.01 mm to about 5 mm, from about 0.1 mm to about 4 mm, or from about 0.2 mm to about 2 mm. The wall thickness may be substantially uniform (e.g., varying by no more than about 15%, no more than about 10%, no more than about 5%, or no more than about 2% over substantially the entire length of the tube). In some embodiments, the wall thickness may vary along the length of the tube.

The flavor substrate in the form of a tube or rod may take various shapes and may have, for example, a cross-sectional shape such as a circle, square, rectangle, oval, triangle, polygon, or the like. Although shown as having a substantially continuous diameter or thickness, in some embodiments, the diameter and/or thickness of the flavor substrate (or wall of the flavor substrate) may vary along its length. For example, the diameter and/or thickness may increase from the first end (101, 101', 101") to the second end (103, 103', 103") such that the diameter and/or thickness of the second end is greater than the diameter and/or thickness of the first end by an amount from about 1% to about 600%, from about 25% to about 500%, from about 50% to about 400%, or from about 75% to about 250%. Alternatively, the diameter and/or thickness may decrease from the first end (101, 101', 101") to the second end (103, 103', 103") such that the diameter and/or thickness of the second end is greater than the diameter of the first end by an amount from about 1% to about 600%, from about 25% to about 500%, from about 50% to about 400%, or from about 75% to about 250%.

The flavor substrate (100, 100', 100") may be configured to provide a substantially large surface area for the passage of flavor liquid from the flavor substrate to an aerosol stream extending along the longitudinal length of the flavor substrate. This may be achieved by providing the flavor substrate in a specific configuration and/or by providing a plurality of flavor substrates in combination. For example, FIG. 3A shows a flavor substrate 100 that is in a folded or pleated configuration. An optional outer sleeve 125 is also shown. As a further example, FIG. 3B shows a flavor substrate 100 that is in an assembled configuration and surrounded by an optional outer sleeve 125. As another example, FIG. 3C shows a flavor substrate 100, which is in a rolled configuration and surrounded by an optional outer sleeve 125. The flavor substrate 100, essentially in the form of a sheet, can be provided in any one or more of the above configurations, as well as in additional similar configurations in which the sheet is aggregated in such a way as to maximize the available surface area over which an aerosol or similar fluid can flow. Although only one sheet is shown as aggregated (e.g., folded, gathered, or rolled), it should be understood that a plurality of sheets (e.g., two, three, four, five, or even more) can be combined. Furthermore, when using a plurality of sheets, two or more individual sheets can be formed from different materials and/or can be designed to or configured to provide different properties. For example, two sheets (or more sheets) configured to provide two or more different flavors may be used to provide a desired flavor combination.

As another example, FIG. 3D shows a plurality of flavor substrates 100' that are formed as rods having a substantially square cross-section (although any profiled cross-section is envisaged) and surrounded by an optional outer sleeve 125. The plurality of rods are shown in the form of a grid, but any packaging method may be used. As another example, FIG. 3E shows a plurality of flavor substrates 100'' that are formed as tubes having a substantially circular cross-section (although any profiled cross-section is envisaged) and surrounded by an optional outer sleeve 125. The plurality of tubes may be equipped with any desired packaging method. As another example, FIG. 3F shows the use of two different types of flavor substrates. A plurality of flavor substrates 100' in the form of rods are included together with one flavor substrate 100" in the form of a tube, all of which are surrounded by an optional outer sleeve 125. Again, the rods and tubes can have any desired cross-section and can be provided in any desired number. In particular, although only one tube 100" of flavor substrate is shown, it should be understood that a plurality of flavor substrate rods 100' can be combined with a plurality of flavor substrate tubes 100". As an additional example, FIG. 3G also shows the use of two different types of flavor substrates. The flavor substrate 100 in the form of a sheet is included in one flavor substrate 100" in the form of a tube, all of which are surrounded by an optional outer sleeve 125. Again, the sheet and tube can have any desired cross-section and can be provided in any desired number (for example, one sheet with a plurality of tubes, one tube with a plurality of sheets, or a plurality of sheets with a plurality of tubes). Similarly, any number of rod(s) 100' and/or tube(s) 100" of the flavor substrate can be combined with any number of sheets 100 of the flavor substrate, which can be folded, gathered, or wrapped.

In some embodiments, the porous material forming the flavor substrate (100, 100', 100") may be formed at least in part from one or more polymeric materials such as polyethersulfone, polypropylene, polyethylene, polyester (e.g., polyethylene terephthalate and polypropylene terephthalate), nylon, polylactic acid (PLA), cellulosic materials (e.g., cellulose nitrate, regenerated cellulose, cellulose acetate), silica, cotton, ceramics, and combinations thereof. Likewise, biodegradable polymers may be used for this purpose. For example, the flavor substrate (100, 100', 100'') may be formed at least in part from fibers formed from any of the above materials individually or in one or more combinations. Likewise, any one or more of the above materials may be expressly excluded from use in one or more embodiments of the present disclosure.

In additional embodiments, the elongated flavor substrate 100 in the flavor delivery device 50 may be formed by one or more layers. More layers may be used, and each layer may be formed by the same or different materials. Additionally, individual layers may be designed for or configured to exhibit specific properties that may be independent of the remaining layers. Each layer may independently exhibit the same or different density, porosity, thickness, materials, or other properties and/or structural features. The elongated flavor substrate 100 may be formed by one layer, two layers, three layers, four layers, or a greater number of layers. When using more than one layer, the layers may be produced using coextrusion or other methods known in the art. In some embodiments, the use of materials having one or more different properties, as noted above, when forming individual layers may be effective in providing desired results, such as providing different release rates of the flavor material. For example, varying release rates between layers may be desirable to create a distinct flavor profile distinct from each individual layer. Specifically, a layer composed of higher-density materials may be effective in providing a relatively slower release of the flavor material entrapped within it, while a layer composed of lower-density materials may be effective in providing a relatively faster release of the flavor material entrapped within it.

According to one or more embodiments, the flavor substrate 100 according to the disclosure of the present invention may comprise or may be substantially formed from a plurality of fibers. The term "fiber" as used herein includes both finite-length fibers, such as conventional staple fibers and nanofibers, as well as substantially continuous structures, such as continuous filaments, unless otherwise specified. The fibers may have a substantially rounded or circular cross-section or non-circular cross-sections (e.g., oval, rectangular, multi-lobed, and the like). The fibers may be provided in various configurations, and, in particular, the fibers may comprise multicomponent fibers. The term "multicomponent fibers" as used herein includes staple and continuous fibers obtained from two or more polymers present in discrete structured domains within the fiber, as opposed to mixtures in which the domains tend to be dispersed, random, or unstructured. For illustrative purposes only, the present invention will generally be described in terms of an exemplary bicomponent fiber comprising two polymer components; however, the disclosure of the present invention also expressly includes fibers with two or more structured components and is not limited to the exemplary bicomponent fibers described below. Although the disclosed embodiments of the invention are not limited to two components, the terms first component and second component are used throughout for convenience of description.

Multicomponent fibers may contain multiple polymer components, which may be arranged in substantially continuously spaced, discrete zones across the cross-section of the multicomponent fiber and extend continuously along the length of the multicomponent fiber. Both the fiber shape and the configuration of the components within it will depend on the equipment used to prepare the fiber, the process conditions, and the melt viscosity of the various components. Various fiber configurations are possible, but the cross-section of a multicomponent fiber may be particularly circular, as the equipment typically used in the production of multicomponent synthetic fibers often produces fibers with substantially circular cross-sections; however, other cross-sections are encompassed.

Non-limiting examples of multicomponent fibers that may be used in a flavor substrate according to the disclosure of the present invention are shown in FIG. 4A and FIG. 4B. FIG. 4A shows a cross-sectional view of an exemplary multicomponent fiber 10 in the form of a sheath/core fiber that includes at least two structured polymeric components: (i) an outer sheath component 2 comprising a first polymer; and (ii) an inner core component 4 comprising a second polymer. The core component 4 may be substantially centrally located within the outer sheath component 2 in a substantially concentric configuration, as shown, or may be offset in a substantially eccentric configuration. FIG. 4B shows another exemplary embodiment of a multicomponent fiber 10 configured as a "matrix" or "islands-in-sea" fiber having a plurality of inner or "island" polymeric components surrounded by an outer matrix or "sea" polymeric component. The island components 4 may be substantially uniformly distributed within the matrix or marine component 2, as shown in FIG. 4B. Alternatively, the island components 4' may be randomly distributed within the marine component 2. In various embodiments, the marine polymer component 2 may comprise a first polymer component, and the island polymer components 4 may comprise a second polymer component.

Methods for producing multicomponent fibers are well known and require no detailed description here. Typically, to form a multicomponent fiber, at least two polymers are extruded separately and fed into a polymer distribution system, where the polymers are introduced into a segmented spinneret plate. The polymers follow separate paths to the fiber spinneret and combine at the spinneret orifice. The spinneret is designed to produce the extrudate with the desired shape.

After extrusion through a die, the resulting thin strands of fluid, or filaments, remain molten for some distance before solidifying by cooling in the surrounding fluid, which can be cooled air blown through the filaments. After solidification, the filaments are collected on a spinning disk or other receiving surface. In a continuous filament process, the strands are collected on a spinning disk, which pulls downward thin streams of fluid proportional to the speed of the receiving disk. In a jet process, the strands are collected in a nozzle, such as an air gun, and blown onto a receiving surface, such as a roller or moving belt, to form a spunbond web. In the meltblown process, air is ejected onto the surface of a spinneret, which serves to simultaneously draw downward and cool thin streams of fluid as they are deposited on the receiving surface in the path of the cooling air, thereby forming a fibrous web. Regardless of the type of melt spinning procedure used, it is important that the thin streams of fluid be drawn downward in a molten state, i.e., before solidification, to reduce the fiber diameter. Melt draw ratios known in the art can be used. When using a continuous process for producing filaments or staple, it may be desirable to draw the strands in the solid state using conventional drawing equipment, such as, for example, successive spinning disks operating at differential speeds. See, for example, U.S. Patent No. 5,082,899, the entire disclosure of which is incorporated herein by reference.

After solid-state drawing, the continuous filaments can be crimped or textured and cut to the desired fiber length, thereby producing staple fibers. Staple fibers typically range in length from about 25 to about 50 millimeters, although the fibers can be longer or shorter as desired. See, for example, U.S. Patent No. 4,789,592 to Taniguchi et al. and U.S. Patent No. 5,336,552 to Strack et al., each of which is incorporated herein by reference in its entirety.

Multicomponent fibers according to various embodiments may be staple fibers, tows, spunbond yarns, continuous filaments, or meltblown fibers. In general, staple, multifilament, and spunbond fibers formed according to the present embodiment may have a fineness of from about 0.5 to about 100 denier. Meltblown yarns may have a fineness of from about 0.001 to about 10.0 denier. Monofilament fibers may have a fineness of from about 50 to about 10,000 denier.

Multicomponent fibers may be incorporated into or formed within the flavor substrate as otherwise described herein. The fibers, for example, may be formed into nonwoven webs by any means suitable in the art, in particular by using heat-bonding. In addition, the continuous filament may be spun directly into nonwoven webs using a spunbonding process. Fibers other than the multicomponent fibers described above may also be present, including any of the various synthetic and/or natural fibers known in the art or otherwise listed in the disclosure of the present invention. Examples of synthetic fibers include polyolefin, polyester, polyamide, acrylic, viscose, cellulose acetate, thermoplastic multicomponent fibers (such as conventional sheath/core fibers, for example, fibers with a polyethylene sheath/polyester core), and the like, and mixtures thereof. Examples of natural fibers include wool, cotton, wood pulp, and the like, and mixtures thereof.

The first polymer component and the second polymer component may be formed from any material as otherwise described herein. In some embodiments, the first polymer component (e.g., forming the sheath or marine component of multicomponent fibers) may be designed to be or configured to be substantially porous. Non-limiting examples of polymers that can be used to make a porous sheath include nylon, polyethylene, polypropylene, polyester, polyimide, polyetheretherketone (PEEK), polyurethane, polytetrafluoroethylene, and Pebax®. These porous materials may be produced using known methods described in the art, such as electrospinning. The second polymer component (e.g., forming the core or island component of multicomponent fibers) may be designed to be or configured to have a flavor material, as described herein, combined therewith and then release the flavor material through the first polymer component. Thus, the shell or marine component may be designed or configured to retain the flavoring material(s) mixed with the second polymeric component for an extended period of time, prolonging the delivery of the flavoring substance. In other words, extended flavoring delivery or controlled flavoring delivery may be achieved such that the flavoring material added to the aerosol flow is substantially continuous over time, rather than experiencing a decrease in flavoring transfer over time.

In one or more embodiments, the flavor substrate 100 may be derived, at least in part, from tobacco material, including, but not limited to, reconstituted tobacco. Suitable reconstituted tobacco may be prepared using any known tobacco reconstitution processes in which tobacco residues are combined and configured into a substantially sheet-like form. An exemplary method for producing reconstituted tobacco is disclosed in U.S. Patent No. 7,900,639 to Perfetti, which is incorporated by reference.

In some embodiments, the flavoring material may contain one or more flavoring agents. As used herein, the term "flavoring agent" refers to compounds or components that may be present in a flavoring material (e.g., a flavoring liquid) that can be delivered to a user and that impart sensory sensations in terms of taste and/or aroma. Examples of flavoring agents include, but are not limited to, vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavorings, including lime and lemon), maple, menthol, mint, peppermint, spearmint, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, rosemary, hibiscus, rose hips, yerba mate, guayusa, honeybush, rooibos, yerba mate, bacopa monnieri, ginkgo biloba, withania somnifera, cinnamon, sandalwood, jasmine, cascarola, cocoa, licorice, and flavoring agents of the type and nature traditionally used to flavor cigarette, cigar, and pipe tobacco, as well as any a combination of the above flavorings. In addition, syrups, such as high fructose corn syrup, may be used. Examples of plant-derived compositions that may be useful are described in U.S. Patent No. 9,107,453 and U.S. Patent Application Publication No. 2012/0152265 to Dube et al., the disclosures of which are incorporated herein by reference in their entireties. The selection of such additional components varies depending on factors such as the sensory characteristics desired in a smoking article, and the present invention encompasses any such additional components that are readily apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See, for example, Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972), and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972), the disclosures of which are incorporated herein by reference in their entireties. For other examples of flavor materials that may be useful in the disclosed products, see, for example, U.S. Patent Application Publication No. 2002/0162562 to Williams; U.S. Patent Application Publication No. 2002/0162563 to Williams; U.S. Patent Application Publication No. 2003/0070687 to Atchley et al.; U.S. Patent Application Publication No. 2004/0020503 to Williams; U.S. Patent Application Publication No. 2005/0178398 to Breslin et al.; U.S. Patent Application Publication No. 2006/0191548 to Strickland et al.; U.S. Patent Application Publication No. 2007/0062549 to Holton, Jr. et al.; U.S. Patent Application Publication No. 2007/0186941 to Holton, Jr., et al.; U.S. Patent Application Publication No. 2007/0186942 to Strickland, et al.; U.S. Patent Application Publication No. 2008/0029110 to Dube, et al.; U.S. Patent Application Publication No. 2008/0029116 to Robinson, et al.; U.S. Patent Application Publication No. 2008/0029117 to Mua, et al.; U.S. Patent Application Publication No. 2008/0173317 to Robinson, et al.; and U.S. Patent Application Publication No. 2008/0209586 to Neilsen, et al., each of which is incorporated herein by reference.

It should be noted that reference to a flavoring agent need not be limited to any single flavoring agent as described above, and may in fact represent a combination of one or more flavoring agents. Furthermore, when using multiple layers and/or types of flavoring substrates as disclosed herein, different flavoring materials may be used on different layers and/or types of flavoring substrates. For example, a flavoring substrate formed from two layers may include different flavoring materials on two different layers.

In one or more embodiments, at least a portion of the flavor material may be provided in one or more rupturable capsules that may be included in the elongated flavor substrate 100 of the flavor delivery device 50. The one or more rupturable capsules may independently carry a payload containing one or more flavor materials, as described above. The flavor material may be released from the rupturable capsule by any suitable action, such as, for example, squeezing the elongated flavor substrate or twisting, bending, or folding all or part of the flavor delivery device 50 or any other method of releasing the flavor substance from the rupturable capsule. If desired, one or more rupturable capsules may be formed from a material that is rupturable during use, for example, as a result of contact with vapor-phase materials in the aerosol and/or as a result of an increase in temperature associated with the passage of the aerosol. Rupture of the capsule(s) results in the release of the contents contained and sealed within the capsule. The release of the contents provides the intended benefit of some of these components, whether this benefit results from aromatization, flavoring, cooling, or humidification of the aerosol.

The rupturable capsule(s) may have any desired shape, such as oval, spherical, or any other conceivable geometry. The rupturable capsule(s) may comprise a rigid outer shell, such as a gelatin outer shell, that surrounds an internal payload. Suitable capsules are commercially available from Mane Aromatic Flavors, Nice, France, as gelatin-encapsulated mixtures of medium chain triglycerides and flavors. Designations for a number of flavor capsules available from Mane Aromatic Flavors include: Spearmint, E209123; Cinnamon, E0303392; Russian Tea, E0303386; Lemon, E127382; and Menthol, E127384. Such representative rupturable capsules have diameters of about 3.5 mm and about 4 mm. The outer shell of the rupturable capsule is preferably made of food-grade gelatin obtained from bovine, fish, or porcine material. A wide range of gelatins can be used, and the choice of gelatin for the outer surface of the capsule is a matter of design choice for those skilled in the art. See "Encyclopedia of Chemical Technology," Kirk-Othmer, 4th ed. 12, 406-416, 1994, which is incorporated herein by reference.

A plurality of degradable capsules may be positioned within the elongated substrate 100 of the flavor delivery device 50. These capsules may contain the same flavor material or a different flavor material to enhance the flavor effect or to produce a different flavor effect. The capsules may be positioned at different locations within the elongated flavor substrate such that the flavor material is released at different times. A plurality of degradable capsules may be positioned at the same location within the elongated flavor substrate 100. For example, several degradable capsules may have significantly different sizes or different geometries, including spherical or oval, so that the flavor material contained within the degradable capsule has a larger diameter. For example, the user may crush the first capsule by squeezing or pressing the flavor substrate to release the first flavor substance. The user may then perform a second squeezing or pressing to crush a second, crushable capsule containing the flavor material. The second capsules may have a smaller diameter than the first capsule, so that the first capsule is crushed with less pressure applied relative to the pressure required to crush the smaller capsules. The second pressing may be performed later and at the user's request to enhance or broaden the flavor effect of the first capsule.

The flavor delivery device 50 may comprise rupturable capsules having a diameter of at least about 1 mm, typically at least about 2 mm, and often at least about 3 mm. Typically, the rupturable capsule may have diameters that do not exceed about 6 mm, often do not exceed 5 mm, and most often do not exceed about 4.5 mm. Particularly preferred rupturable capsules have diameters in the range of about 3 mm to about 5 mm in diameter, and particularly preferred rupturable capsules have a diameter of about 4.5 mm.

According to one or more embodiments, the flavor delivery device 50 may also include an outer sleeve 125 that substantially surrounds the outer perimeter of the elongated flavor substrate 100. The outer sleeve 125 may be provided in such a way that it substantially surrounds the flavor substrate(s). Preferably, the outer sleeve 125 is present along substantially the entire longitudinal length L of the flavor substrate 100. However, it should be understood that the outer sleeve 125 may be present only along a partial length of the elongated flavor substrate 100, for example, only along approximately the middle of the longitudinal length of the flavor substrate or only near one end of the flavor substrate. As non-limiting examples, the outer sleeve 125 may be in the form of a sheet that can be substantially wrapped around a substrate or a combination of substrates, and the wrapped sheet can be glued, sewn, welded, or otherwise attached to one or more substrates and/or to itself. As an additional example, the outer sleeve 125 can be formed substantially in the form of a tube, straw, or the like and can slide around the substrate(s), or the substrate(s) can be located or can be located in the tube. The outer sleeve 125 can vary in thickness, and the thickness can be substantially constant along its entire length or can vary. In some embodiments, the outer sleeve can have a thickness of from about 25 microns to about 2 mm, from about 50 microns to about 1 mm, or from about 100 microns to about 750 microns. In additional embodiments, a substantially thicker material can be used.

In some embodiments, the outer sleeve 125, which surrounds the outer perimeter of the elongated flavor substrate 100, may be formed at least in part from one or more polymeric materials, such as polyester, polyester, polypropylene, polylactic acid (PLA), nylon, or a combination thereof. For example, the outer sleeve 125 may be formed at least in part from fibers formed from any of the above materials alone or in one or more combinations. Likewise, any one or more of the above materials may be expressly excluded from use in one or more embodiments of the present disclosure. The outer sleeve, in particular, may be formed from a biodegradable material. In other examples, the outer sleeve may be formed from materials other than a polymeric material. For example, in some embodiments, the outer sleeve may be formed from paper foil, filter paper, ceramic, aluminum, or any combination thereof. Combinations of polymeric materials and non-polymeric materials may also be used. In one or more embodiments, the outer sleeve 125 may be, in particular, designed to or configured to substantially prevent or impede the passage of any flavoring material therethrough for an extended period of time (e.g., up to about 6 months, about 1 year, or about 2 years) under ambient conditions. Thus, the outer sleeve 125 may be substantially impermeable to one or both aqueous liquids and oils for at least the minimum time, as noted above.

A flavor delivery device in combination with a flavor substrate and a flavor material may be particularly suitable, according to embodiments of the present disclosure, for combination with other articles, such as aerosol delivery devices in various forms. Thus, the flavor substrate and the flavor material may be provided in a form in which the flavor substrate can be easily combined with such additional devices. For example, in some embodiments, the flavor substrate may be configured to be combined with an outer shell that is intended for or configured to remove or permanently retain the flavor substrate. In the embodiment shown in FIG. 5, the flavor delivery device 500 according to the exemplary embodiment may comprise an outer casing 510 that comprises a body 501 and a mouthpiece portion 502. The body 501 extends along the longitudinal axis between a distal end 511 and a proximal end 513, where both ends comprise one or more openings 512 and 514, respectively. The outer casing forms a chamber 515 therein. The mouthpiece portion 502 may be attached to the proximal end 513 of the body portion 501 and may include one or more openings 503 formed therein. Thus, the mouthpiece portion 502 may be permanently attached to the body portion 501, removably attached (including hingedly attached), or may be co-extruded with the body portion to be a single monolithic structure. The outer casing 510 may have one or more openings 520 formed within its body 501.

FIG. 6 shows an exploded view of, for example, a flavor delivery device 500 according to the present disclosure, including a flavor substrate 100, which may have an outer sleeve surrounding at least a portion of the flavor substrate. As shown in the figure, at least one destructible capsule 525 containing a flavoring agent is optionally contained within the flavor substrate 100. The flavor substrate 100 may include a flavoring material, and such flavoring material may be the same as or different from the flavoring material present in the at least one destructible capsule 525. Alternatively, the flavor substrate may exclude any flavoring material except the flavoring material that is present within the at least one destructible capsule 525. The flavor substrate 100 may be located within the chamber 515 of the outer casing 510. Once inside the chamber 515 of the outer casing 510, the flavoring material present in the flavor substrate 100 and/or at least one rupturable capsule 525, can be released by passing a flow therethrough, such as an aerosol flow. For example, the rupturable capsule 525 can be broken by squeezing the elongated flavor substrate 100 or by twisting, bending, folding the flavor delivery device 500 (or only a part thereof) or in any other way to release the flavor substance from the rupturable capsule. The elongated flavor substrate is removable and replaceable. Preferably, at least one elongated flavor substrate, for example, the flavor substrate 100, is located within the chamber 515 of the outer casing 510 such that the longitudinal axis of the at least one elongated substrate is substantially parallel to the longitudinal axis of the outer casing. The flavor delivery device 500 thus formed may then be engaged with a mouthpiece end or configured to be inserted into a smoking article or similar device, such that vapor or aerosol generated in the delivery device may pass through an opening 512 in the outer casing 510 of the flavor delivery device 500, and flavor material held by, for example, the flavor substrate 100 and/or the crushable capsule(s) may be captured in the vapor or aerosol, which then exits the flavor delivery device through at least one opening 503 in the mouthpiece portion 502 of the flavor delivery device.

In one or more embodiments, the capsule or capsules used herein may be in the form of a microcapsule or a plurality of microcapsules that may contain a flavoring material. For example, microcapsules may be particularly useful for storing a flavoring material and subsequently releasing it without the need for mechanical action. In other words, the release of the flavoring material from the microcapsules may be caused by contact with a passing aerosol stream (e.g., by heat, moisture, or a chemical reaction that causes the microcapsules to release the flavoring material). Encapsulation of the flavoring material can be accomplished using any suitable technology. For example, microcapsules can be prepared using any of a variety of chemical encapsulation technologies, such as solvent evaporation, solvent extraction, organic phase separation, interfacial polymerization, simple and complex coacervation, in-situ polymerization, liposome encapsulation, and nanoencapsulation. Alternatively, physical encapsulation methods such as spray coating, pan coating, fluidized bed coating, ring spray coating, spinning disk spraying, spray cooling, spray drying, spray cooling, fixed-nozzle coextrusion, centrifugal die coextrusion, or submerged-nozzle coextrusion may be used.

Regardless of the encapsulation method used, the outer wall or shell material and the solvents used to form the capsules can vary. Classes of materials commonly used as wall or shell materials include proteins, polysaccharides, starches, waxes, fats, natural and synthetic polymers, and resins. Examples of materials for use in the microencapsulation method used to form microcapsules include gelatin, acacia, polyvinyl acetate, potassium alginate, locust bean gum, potassium citrate, carrageenan, potassium polymetaphosphate, citric acid, potassium tripolyphosphate, dextrin, polyvinyl alcohol, povidone, dimethylpolysiloxane, dimethyl silicone, refined paraffin wax, ethyl cellulose, bleached shellac, modified food starch, sodium alginate, guar gum, sodium, sodium citrate, carboxymethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methyl cellulose, sodium ferrocyanide, sodium polyphosphates, locust bean gum, methyl cellulose, sodium trimetaphosphate, methyl ethyl cellulose, sodium tripolyphosphate, microcrystalline wax, tannic acid, petroleum wax, terpene resin, tragacanth, polyethylene, xanthan gum and polyethylene glycol.

Microcapsules are commercially available, and the types of microcapsule manufacturing technologies exemplified are those described in Gutcho, Microcapsules and Microencapsulation Techniques (1976); Gutcho, Microcapsules and Other Capsules Advances Since 1975 (1979); Kondo, Microcapsule Processing and Technology (1979); Iwamoto et al., AAPS Pharm. Sci. Tech. 2002 3(3): Article 25; U.S. Pat. Nos. 5,004,595 to Cherukuri et al.; 5,690,990 to Bonner; #5,759,599 by Wampler et al.; #6,039,901 by Soper et al.; #6,045,835 by Soper et al.; #6,056,992 by Lew; #6,106,875 by Soper et al.; #6,117,455 by Takada et al.; #6,482,433 by DeRoos et al.; and #6,929,814 by Bouwmeesters et al.; each of which is incorporated herein by reference.

The flavor delivery device is advantageously useful for imparting a desired flavor effect to the aerosol stream. Thus, the flavor delivery device can be combined with any type of device configured to provide an aerosol flow. In exemplary embodiments, this may include an aerosol delivery device such as those further described herein, or one having different configurations of parts, but designed to provide the same function of acting on a liquid aerosol precursor to form a vapor that can be entrained in the passing air stream and thus form an aerosol. For example, with reference to FIG. 7, when the cartridge 404 is engaged with the power unit, a user drawing through the opening 428 at the mouthpiece end of the cartridge will cause air to flow through the air inlet 418. Air may flow through and/or around reservoir 444 and capture vapor generated by heating the aerosol precursor composition in liquid transfer element 436 by heater 434, thereby forming an aerosol that exits through opening 428. Thus, one or more airflow passages may be provided through the aerosol delivery device. As just described, heater 434 may be positioned substantially within the airflow passage so that the generated vapor is effectively available for drawing into the air flowing through cartridge 404.

In one or more embodiments, mouthpiece 419 is provided in accordance with the disclosure of the present

invention, and the mouthpiece 419 may be designed for or configured to connect to the mouthpiece end of the cartridge 425 in FIG. 7. In some embodiments, the flavor delivery device 200, as described herein, may be located substantially within the air flow passage. For example, in some embodiments, as shown in FIG. 7, the flavor delivery device 200 may be located within the cartridge 425 near the mouthpiece end thereof. In further embodiments, the flavor delivery device 200 may be configured as described above with respect to FIG. 5 and FIG. 6 (or a similar configuration) and function substantially as a mouthpiece for the aerosol delivery device. In another embodiment, the flavor delivery device may be located above a mouthpiece connected to the mouthpiece end of the cartridge housing. Thus, the mouthpiece may be configured to be inserted into the end of the aerosol delivery device and/or may be configured to at least partially slide over the end of the aerosol delivery device to form a connection therewith. In one or more embodiments, the flavor delivery device 200 may be provided as a separate unit that can be combined with other devices as desired to add a flavor to an unflavored aerosol or to provide an additional flavor to be mixed with the flavor already provided by the associated device. In addition, the flavor delivery device may be designed for or configured to be removably attached to one or both of the mouthpiece end of the cartridge 425 and the mouthpiece end of the mouthpiece 419 attached to the mouthpiece end of the cartridge. Such a connection may be achieved by any one or more of a threaded connection, a magnetic connection, a push-fit (or friction fit) connection, etc. Thus, the flavor delivery device is user-replaceable.

Aerosol delivery devices comprising flavored devices according to the disclosure of the present invention may typically include a number of components located within an outer shell or housing. The overall design of the outer shell or housing may vary, and the configuration and format of the outer housing, which may determine the overall size and shape of the aerosol delivery device, may also vary. Typically, an elongated housing resembling the shape of a cigarette or cigar may be formed from a single, integral shell; or the elongated housing may be formed from two or more separable components. For example, an aerosol delivery device may comprise an elongated shell or housing that may be substantially tubular in shape and accordingly resemble the shape of a conventional cigarette or cigar. However, in other embodiments of the invention, various other shapes and configurations may be used (for example, a rectangular shape or a keychain shape). Thus, an aerosol delivery device as described herein may adopt any desired configuration.

In one embodiment, all components of the aerosol delivery device are located within a single outer housing, which may be referred to as a casing or shell. In an alternative embodiment, the aerosol delivery device may comprise two or more shells that are connected and detachable. For example, the aerosol delivery device may comprise a control housing or power supply unit that includes a shell containing one or more reusable components (e.g., a rechargeable battery and various electronics for controlling the operation of the product), and may also comprise a detachably attached shell configured as a replaceable part (e.g., a replaceable cartridge containing flavor additives). More specific formats, configurations, and arrangements of components within a single shell or in a detachable multi-component shell will be apparent in light of the further disclosure of the invention presented herein. Furthermore, various designs of the aerosol delivery device and component arrangements may be understood by considering commercially available electronic aerosol delivery devices.

The aerosol delivery devices of the present invention may comprise some combination of a power source (i.e., an electrical power source), at least one control component (e.g., means for actuating, controlling, regulating, and/or shutting off power to generate heat, such as by controlling an electrical current passing from the power source to other components of the aerosol delivery device), a heater or heat-generating component (e.g., an electrical resistive or inductive heating element, or a component commonly referred to as part of an "atomizer"), and an aerosol precursor composition (e.g., typically a liquid capable of generating an aerosol when exposed to a sufficient amount of heat, such as ingredients commonly referred to as "smoking juice," "e-liquid," and "e-juice"), and a mouthpiece region or end for allowing a puff to be taken from the aerosol delivery device to inhale the aerosol (e.g., a predetermined airflow path through the article such that the generated aerosol can be extracted therethrough upon puffing).

The alignment of the components within the proposed aerosol delivery device may vary. In specific embodiments, the aerosol precursor composition may be located near the end of the aerosol delivery device, which may be configured to be positioned closer to the user's mouth to increase aerosol delivery to the user. However, other configurations are not excluded. Typically, a heating element may be positioned close enough to the aerosol precursor composition that heat from the heating element can vaporize the aerosol precursor (which may itself contain one or more flavoring agents, medicinal agents, or other additives) and form an aerosol for delivery to the user. When the heating element heats the aerosol precursor composition, the aerosol is formed, released, or formed into a physical form suitable for inhalation by the consumer. It should be noted that the above terms should be considered interchangeable, so that forms of the specified term such as "release", "release", "releases" or "released" include forms such as "form" or "generate", "forming" or "generating", "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, and such terms are also interchangeable in this application except where otherwise indicated.

As noted above, the aerosol delivery device may comprise a battery and/or other power source (e.g., a capacitor) for supplying sufficient electrical current to support the various functionalities of the aerosol delivery device, such as powering the heater, powering the control systems, powering the indicators, and the like. The power source may be configured in accordance with various embodiments. In one example, the power source is configured to supply sufficient energy to rapidly heat the heating element to generate an aerosol and to power the aerosol delivery device for use for the required period of time. The power source may be sized to fit comfortably within the aerosol delivery device so that the aerosol delivery device can be conveniently used. Furthermore, in one embodiment, the power source is sufficiently lightweight to not interfere with the smoking process.

More specific formats, configurations, and arrangements of components within the aerosol delivery device according to the present invention will be apparent in light of the further disclosure of the invention presented below. Furthermore, the selection of various components of the aerosol delivery devices may be understood by considering commercially available electronic aerosol delivery devices. Furthermore, the arrangement of components in the aerosol delivery device may also be understood after considering commercially available electronic aerosol delivery devices. Examples of commercially available products for which their components, methods of their operation, materials included therein, and/or other attributes thereof may be included in the devices according to the present invention, as well as manufacturers, developers, and/or patent holders of components and related technologies that may be used in the aerosol delivery device according to the present invention, are described in U.S. Patent Application No. 15/222,615, filed July 28, 2016, by Watson et al., which is fully incorporated herein by reference.

One example of an embodiment of an aerosol delivery device 400, illustrating components that can be used in an aerosol delivery device according to the disclosure of the present invention, is shown in FIG. 7. As can be seen from the partially cutaway image, the aerosol delivery device 400 can comprise a power supply unit 402 and a cartridge 425, which can be aligned in a permanent or detachable manner. The interaction of the power supply unit 402 with the cartridge 425 can be a tight fit (as shown), a threaded interaction, an interference fit, a magnetic interaction, or the like. In particular, connection components such as those further described herein can be used. For example, the power supply unit can comprise a mating element that is configured to interact with a connector on the cartridge.

In specific embodiments, the power supply 402 and/or the cartridge 425 may be referred to as disposable or reusable. For example, the power supply may have a replaceable battery or a rechargeable battery and, thus, may be combined with any type of charger, including a connection to a typical electrical network, a connection to a car charger (i.e., a cigarette lighter receptacle), and a connection to a computer, such as via a universal serial bus (USB) cable. For example, an adapter including a USB connector at one end and a power supply connector at the opposite end is disclosed in U.S. Patent Application Publication No. 2014/0261495 to Novak et al., which is incorporated herein by reference in its entirety. Furthermore, according to some embodiments, the cartridge may comprise a disposable cartridge, as described in U.S. Patent No. 8,910,639 (Chang et al.), which is incorporated herein by reference in its entirety.

As shown in FIG. 7, the power supply unit 402 can be formed from a power supply housing 401, which can contain a control component 406 (for example, a printed circuit board (PCB), an integrated circuit, a memory component, a microcontroller, and the like), a flow sensor 408, a battery 410, and a light-emitting diode 412, and such components can be aligned in various ways. Additional indicators (for example, a tactile feedback component, an audio feedback component, or the like) can be contained in addition to or as an alternative to the light-emitting diode. Additional representative types of components that provide visual signals or indicators, such as light-emitting diode components, and their construction and use are described in U.S. Patent Nos. 5,154,192 to Sprinkel et al., 8,499,766 to Newton, and 8,539,959 to Scatterday, and in U.S. Patent Publication No. 2015/0020825 to Galloway et al. and in U.S. Patent Publication No. 2015/0216233 to Sears et al., which are incorporated herein by reference.

The cartridge 425 may be formed by a cartridge shell 403, which encloses a reservoir 444, which is in fluid communication with a liquid transfer element 436, which is capable of wicking or otherwise transporting an aerosol precursor composition stored in the reservoir housing to a heater 434. The liquid transfer element may be formed from one or more materials capable of transferring liquid, for example, by capillary action. The liquid transfer element may be formed, for example, from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, fiberglass), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, glass-ceramic beads, capillary tubes, and the like. Thus, the fluid transport element may be any material that contains a network of open pores (i.e., a plurality of pores that are interconnected so that fluid can flow from one pore to another in multiple directions through the element).

Various embodiments of materials capable of generating heat when an electric current is passed through them can be used to form the resistive heating element 434. Examples of materials from which the wire coil can be made include fechral (FeCrAl), nichrome, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo(Si,Al)2), titanium, platinum, silver, palladium, graphite and graphite-based materials (e.g., carbon-based foams and filaments), and ceramics (e.g., ceramics with a positive or negative temperature coefficient). Other embodiments of the heating element can be used in a similar manner. For example, a metal mesh can be located around a cylindrical wick, or a ribbon-shaped metal mesh can be located on a ribbon-shaped or sheet-shaped wick. For example, the heating element can be configured to heat an aerosol precursor composition located within the liquid transport element by radiant heating, as described in U.S. Patent Application Publication No. 2017/0020193, filed December 3, 2015, which is incorporated herein by reference. In other embodiments, the heating element can be configured to heat the aerosol precursor composition by induction heating, as described in U.S. Patent Application Publication No. 2017/0127722, filed November 6, 2015, which is incorporated herein by reference in its entirety. Various heater components can be used in the present aerosol delivery device. In various embodiments, one or more microheaters or similar solid-state heaters can be used. Microheaters and atomizers containing microheaters suitable for use in the disclosed devices are described in U.S. Patent No. 8,881,737 to Collett et al., which is incorporated herein by reference.

An opening 418 may be located in the cartridge shell 403 (e.g., at the tip of the mouthpiece) to allow the generated aerosol to exit the cartridge 404. Such components are a typical example of components that may be present in the cartridge and are not intended to limit the scope of the cartridge components covered by the disclosure of the present invention.

Cartridge 425 may also contain one or more electronic components 450, which may include an integrated circuit, a memory component, a sensor, or the like. Electronic component 450 may be configured to communicate with control component 406 and/or an external device via wired or wireless means. Electronic component 450 may be located anywhere in cartridge 425 or its base 440.

Although the control component 406 and the flow sensor 408 are shown separately, it should be understood that the control component and the flow sensor can be combined on an electronic circuit board with the air flow sensor attached directly to it. In addition, the electronic circuit board can be positioned horizontally relative to the illustration of FIG. 7, in which the electronic circuit board can be longitudinally parallel to the central axis of the power supply. According to some embodiments, the air flow sensor can comprise its own circuit board or other element as a substrate to which it can be attached. In some embodiments, a flexible circuit board can be used. The flexible circuit board can be made in various shapes, including substantially tubular shapes.

The power supply unit 402 and the cartridge 425 may comprise components configured to facilitate fluid interaction with each other. As shown in FIG. 7, the power supply unit 402 may comprise a coupling element 424 having a cavity 404 therein. The cartridge 425 may comprise a base 440 configured to interact with the coupling element 424 and may include a projection 426 configured to be embedded in the cavity 404. Such interaction may facilitate a stable connection between the power supply unit 402 and the cartridge 404 and the establishment of an electrical connection between the battery 410 and the control component 406 in the power supply unit and the heater 434 in the cartridge. In addition, the power supply unit casing 401 may comprise an air inlet 428, which may be a recess in the casing in which it is connected to the mating element 424, which allows air to pass from the environment around the mating element into the casing, where it then passes through the cavity 404 of the mating element into the cartridge through the protrusion 426.

A connecting element and a base suitable for use according to the disclosure of the present invention are described in U.S. Patent Application Publication No. 2014/0261495 to Novak et al., the disclosure of which is incorporated herein by reference in its entirety. For example, a mating element, as shown in FIG. 7, may define an outer periphery 441 configured to mate with an inner periphery 442 of a base 440. According to one embodiment, the inner peripheral portion of the base may have a radius that is substantially equal to or slightly larger than the radius of the outer peripheral portion of the coupling. In addition, the mating element 424 may define one or more projections 429 on the outer periphery 426 configured to interact with one or more recesses 478 formed in the inner periphery of the base. However, various other embodiments of structures, shapes and components may be used to connect the base to the coupling. In some embodiments, the connection between the base 440 of the cartridge 425 and the coupling element 424 of the power supply unit 402 may be substantially permanent, while in other embodiments, said connection between them may be detachable, so that, for example, the power supply unit may be reused with one or more additional cartridges, which may be disposable and/or reusable.

In some embodiments, the aerosol delivery device 400 may be substantially rod-shaped, substantially tubular, or substantially cylindrical. Other embodiments accommodate other shapes and sizes, such as rectangular or triangular cross-sections, polygonal shapes, or the like. In particular, the power supply unit 402 may not be rod-shaped, but may be substantially rectangular, circular, or have some other shape. Similarly, the power supply unit 402 may be substantially larger than the power supply unit, which is expected to be the size of a typical cigarette.

The reservoir 444 shown in FIG. 7 may be a container (e.g., formed by walls that are substantially impermeable to the aerosol precursor composition) or a fibrous reservoir. The walls of the containers may be flexible and foldable. Alternatively, the walls of the container may be substantially rigid. The reservoir of the container may be referred to as a receptacle. In addition, a fibrous material may be provided in at least a portion of the container. In embodiments, the reservoir 444 may comprise one or more layers of non-woven fibers and may be substantially formed in the form of a tube that encloses the interior of the cartridge shell 403. The aerosol precursor composition may be retained in the reservoir 444. Liquid components, for example, may be retained by the reservoir 444 with the possibility of sorption (i.e., when the reservoir 444 comprises a fibrous material). The reservoir 444 may be fluidly connected to the liquid transfer element 436. In this example, the liquid transfer element 436 can transfer the aerosol precursor composition stored in the reservoir 444 by capillary action to the heating element 434, which in this embodiment is a coil of metal wire. Typically, the heating element 434 is located in a heating device with the liquid transfer element 436.

In use, when a user draws on the article 400, an air flow is detected by the flow sensor 408, and the heating element 434 is activated and the components of the aerosol precursor composition are vaporized by the heating element 434. Drawing through the mouthpiece end of the article 400 causes air from the environment to enter the air inlet 418 and pass through the cavity 404 in the coupling element 424 and the central opening in the projection 426 of the base 440. In the cartridge 425, the drawn air is combined with the generated vapor to create an aerosol. The aerosol is entrained, aspirated, or otherwise diverted from the heating element 434 and exits from the mouthpiece opening 428 at the mouthpiece end of the article 400.

An input element may be included in the aerosol delivery device. The input may be included to allow a user to control functions of the device and/or to display information to the user. Any component or combination of components may be used as an input to control a function of the device. For example, one or more push buttons may be used, as described in US Publication No. 2015/0245658 to Worm et al., which is incorporated herein by reference. Similarly, a touch screen may be used, as described in US Patent Application No. 14/643,626, filed March 10, 2015 to Sears et al., which is incorporated herein by reference. As a further example, components configured to recognize gestures based on predetermined movements of the aerosol delivery device may be used as an input device. See US Publication No. 2016/0158782 to Henry et al., which is incorporated herein by reference.

In another aspect, the present invention may be directed to kits that provide various components as described herein. For example, a kit may comprise a control housing with one or more cartridges. The kit may also comprise a control housing with one or more charging components. The kit may also comprise a control housing with one or more batteries. The kit may also comprise a control housing with one or more cartridges and one or more charging components and/or one or more batteries.

In additional embodiments, a kit may comprise a plurality of cartridges. A kit may also comprise a plurality of cartridges and one or more batteries and/or one or more charging components. Kits may also include a case (or other packaging, carrying, or storage component) that houses one or more additional kit components. The case may be a reusable hard or soft container. Furthermore, the case may simply be a box or other packaging structure.

In additional embodiments, the disclosed kits may comprise one or more flavor delivery device components as described herein. For example, a kit may comprise one or more outer casings and one or more flavor substrates. Similarly, a kit may comprise one or more e-liquid containers that may be configured to be combined with a flavor substrate. Furthermore, the outer casing(s), substrate(s), and e-liquid container(s) may be included in any combination with the other kit components described above.

The preceding description of the use of the device may be applied to various embodiments of the invention described in this application, with minor modifications, which may be apparent to those skilled in the art in light of the additional description provided in this application. The above description of use, however, is not intended to limit the use of the specified product, but is provided to meet all the necessary requirements of the disclosure of the present invention.

The use of the terms "about" and "substantially" in this document is intended to indicate that a parameter exactly corresponds to the stated condition or differs from the stated condition by relatively small deviations that would be recognized as arising from typical manufacturing practices and/or sampling errors. For example, a value stated as "about" the stated value is intended to cover the stated value as well as small deviations therefrom, such as +/- 3%, +/- 2%, +/- 1%, +/- 0.5%, or +/- 0.1% of the stated value. Similarly, an item discussed in this document as having "substantially" the stated condition is intended to cover the stated condition as well as small deviations therefrom that may arise from manufacturing practices or the like.

Numerous modifications and other embodiments of the present invention will be apparent to those skilled in the art, using the disclosures provided in the above description and the accompanying drawings. It is therefore to be understood that the invention is not limited to the specific embodiments disclosed herein, and modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are used herein, they are used in a general and descriptive sense only, and not for purposes of limitation.

Claims (37)

1. A device for delivering a flavoring substance, comprising: at least one flavor substrate formed from a porous material and extending along a longitudinal axis between a first end and an opposite second end; flavoring material included in the flavoring substrate; an outer sleeve surrounding the outer perimeter of said at least flavoring substrate, wherein the outer sleeve is impermeable to the flavoring material, and an outer casing extending along a longitudinal axis between a distal end including at least one opening and a proximal end including at least one opening, wherein the outer casing comprises an outer wall defining a chamber, wherein said at least one flavor substrate is located within the chamber of the outer casing such that the longitudinal axis of said at least one substrate is parallel to the longitudinal axis of the outer casing; wherein one of the near end and the far end of the outer casing is designed with the possibility of engaging with the mouthpiece end of the smoking article. 2. A device for delivering a flavoring substance according to claim 1, in which one or more of the following conditions are met: at least one flavor substrate contains one or more rods; at least one flavor substrate comprises one or more tubes; at least one flavoring substrate is made in the form of a sheet with folds; at least one flavoring substrate is in the form of an assembled sheet; at least one flavoring substrate is made in the form of a rolled sheet. 3. The flavor delivery device of claim 1, wherein the porous material that forms at least one flavor substrate is a polymeric material. 4. The flavor delivery device of claim 3, wherein the polymeric material is selected from the group consisting of polyethylene, polypropylene, polyester, polyester, polylactic acid (PLA), acetyl cellulose, nylon, ceramic, or any combination thereof. 5. The flavor delivery device of claim 1, wherein the outer sleeve is made of a material selected from the group consisting of silicone, polyester, polyester, polypropylene, polylactic acid (PLA), nylon, or any combination thereof. 6. A device for delivering a flavoring substance according to claim 1, wherein at least one flavoring substrate is formed by a plurality of layers. 7. The flavor delivery device of claim 6, wherein each layer comprises materials with different densities. 8. The flavor delivery device of claim 6, wherein each layer in the plurality of layers is configured to release the flavor material at different rates. 9. The flavor delivery device of claim 6, wherein each layer in the plurality of layers comprises a different flavor material. 10. The flavor delivery device of claim 1, wherein at least one flavor substrate is made from a plurality of fibers. 11. A flavor delivery device according to any one of claims 1-10, wherein at least a portion of the plurality of fibers are sheath-core fibers. 12. The flavor delivery device of claim 11, wherein the shell is a porous material and wherein the flavor material is included in the core. 13. The flavor delivery device of claim 1, wherein the outer casing comprises one or more openings formed within the outer wall of the casing. 14. The flavoring substance delivery device of claim 1, wherein the flavoring substrate is removable and replaceable. 15. A flavor delivery device according to any one of claims 1-14, wherein at least a portion of the flavor material is contained in a destructible capsule. 16. The flavor delivery device of claim 15, wherein the device includes a plurality of capsules configured to be destructible. 17. The flavor delivery device of claim 16, wherein the plurality of destructible capsules comprise capsules of at least two different sizes. 18. A cartridge for an aerosol delivery device comprising: a cartridge casing having a mouthpiece end; an aerosol precursor composition located inside the housing; an atomizer configured to evaporate the aerosol precursor composition; and a flavoring agent delivery device according to claim 1, arranged in such a way that the evaporated aerosol precursor composition passes through it. 19. The cartridge of claim 18, further comprising a mouthpiece connected to the mouthpiece end of the cartridge housing. 20. The cartridge of claim 19, wherein the mouthpiece comprises said flavor delivery device. 21. The cartridge of claim 20, wherein the flavor delivery device is located above the mouthpiece. 22. The cartridge of claim 18, wherein the flavor delivery device is removable and replaceable. 23. The cartridge of claim 19, wherein the flavor delivery device is releasably connected to one or both of the mouthpiece end of the cartridge and the mouthpiece by any one or more of a threaded connection, a magnetic connection, and a friction fit.