RU2801679C2 - Aerosol supply system with electrical power supply - Google Patents

Abstract

FIELD: tobacco industry.

SUBSTANCE: group of inventions relates to an aerosol supply system and a method for the formation of such a system. The aerosol supply system contains a part in the form of a controlling case, containing the first elongated tubular element with opposite ends, and an energy source placed in it, and a part in the form of a cartridge case, containing the second tubular element with opposite the first and the second ends, wherein the first end is engaged with one of opposite ends of the part in the form of the controlling case. The part in the form of the cartridge case additionally contains the first aerosol formation device placed inside the second tubular element and made with the possibility of functional interaction with the energy source after engagement between one of opposite ends of the part in the form of the controlling case and the first end of the part in the form of the cartridge case, the second end of the part in the form of the cartridge case faces the end of the aerosol supply system, interacting with the mouth. The second aerosol formation device is placed between the first aerosol formation device and the end of the aerosol supply system, interacting with the mouth. The second aerosol formation device is made engaged with the possibility of disconnection with the part in the form of the cartridge case or placed inside the second tubular element of the part in the form of the cartridge case. The first separating element is placed inside the second tubular element between the first aerosol formation device and the second aerosol formation device.

EFFECT: possibility of retraction of aerosol, which is highly fragrant and does not contain sufficient amounts of pyrolysis and incomplete combustion products occurring in tobacco burning.

60 cl, 9 dwg

Description

BACKGROUND OF THE INVENTION

Technical field

The present invention relates to aerosol delivery devices and systems such as smoking articles; and more specifically, aerosol delivery devices and systems that use electrically generated heat to produce an aerosol (eg, smoking products, commonly referred to as electronic cigarettes). Aerosol delivery devices and systems may be configured to heat a substance to be aerosolized containing materials that may, although not necessarily, be made from or derived from tobacco or otherwise contain tobacco and that are capable of being vaporized to form a respirable aerosol for human consumption.

State of the art

Many smoking articles have been proposed over the years as improvements to smoking articles or alternatives to smoking articles based on tobacco combustion. Many of these have been specifically designed to provide the sensations associated with smoking a cigarette, cigar, or pipe without delivering the significant amounts of pyrolysis and incomplete combustion products that occur when tobacco is burned. To this end, numerous smoking articles, flavor generators, and medical inhalers have been proposed that use electrical energy to vaporize or heat volatile material, or to attempt to create the sensation of smoking a cigarette, cigar, or pipe without burning tobacco to a significant extent. See, for example, various alternative smoking articles, aerosol delivery devices, and heat generation sources formulated in the state of the art and described in US Pat. etc.) and No. 2014/0096781 (Sears and others), the contents of which are incorporated into this application by reference. See also, for example, various types of smoking articles, aerosol dispensers, and electrically powered heat sources whose trademark and commercial source are cited in U.S. Patent Application No. 14/170,838 filed Feb. 3, 2014 (Bless and etc.), the contents of which are incorporated into this application by reference.

It would be desirable to provide a powered aerosol delivery system capable of enabling a user of the system to draw an aerosol that is highly aromatic. It may also be desirable to deliver the aerosol in pleasant or comfortable conditions by drawing it into the user's mouth.

Disclosure of the essence of the invention

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

The above and other needs are met by the features of the present invention, which, according to one aspect of the invention, provides an aerosol delivery system. Such an aerosol delivery system may include a control housing portion, the control housing portion comprising a first elongated tubular member having opposite ends and a power source housed therein. Part in the form of a cartridge body contains a second tubular element having opposite first and second ends. One of the first and second ends of the cartridge body part is releasably engaged with one of the opposite ends of the control body part. The cartridge body part further comprises a first aerosol generation device placed inside the second tubular element and configured to be operatively interacted with the energy source after engagement between one of the opposite ends of the control body part and one of the first and second ends of the body part. cartridge. The other end of the first and second ends of the cartridge body portion is further configured as a mouth engaging end. The cartridge body portion further comprises a second aerosol generating device within a second tubular member positioned between the first aerosol generating device and the mouth engaging end. According to certain aspects of the invention, the second aerosol generating device may further comprise one or more aerosol generating elements, wherein the one or more (at least one) aerosol generating elements may be selected from the group consisting of granules, tablets, spherical particles. shapes, discrete small particles, carbon pieces, molded charcoal pieces, spherical ceramic particles, marumarized tobacco leaf pieces, extruded or compressed cylindrical or spherical elements, shredded tobacco leaf, fillers, flavors, visible aerosol forming materials, binders materials, egg-shaped elements, irregularly shaped elements, crushed pieces, flakes, tobacco-containing elements, elements containing visible aerosol forming material, absorbent material objects, absorbent material objects, microcapsules, honeycomb monolith, single porous structure and combinations thereof.

As another feature of the present invention, a method for forming an aerosol supply system is provided. Such a method may include releasably engaging one end of the first elongated tubular element with the first end of the second tubular element, wherein the first elongated tubular element is formed as part in the form of a control housing with an energy source placed inside it, and the second tubular element is formed as part in the form of a housing a cartridge with a first aerosol generating device placed inside it. The first aerosol generating device is operatively engaged with the power source after being engaged between one end of the control body part and the first end of the cartridge body part. The method may also include inserting a second aerosol generating device within a second tubular element of the cartridge body portion, between the first aerosol generating device and a second end of the second tubular, the second end opposed to the first end and formed as a mouth-engaging end. In some instances, inserting the second aerosol generating device within the second tubular may further include inserting one or more aerosol generating elements at least partially forming the second aerosol generating device into the second tubular, the one or more (according to at least one) aerosol forming elements may be selected from the group consisting of granules, tablets, spherical particles, discrete small particles, carbon pieces, molded carbon pieces, spherical ceramic particles, marumerized tobacco leaf pieces, extruded or compressed cylindrical or spherical elements, shredded tobacco leaf, fillers, flavorings, visible aerosol forming materials, binder materials, egg-shaped elements, irregularly shaped elements, crushed pieces, flakes, tobacco-containing elements, elements containing material forming a visible aerosol, absorbent material items, absorbent material items material, microcapsules, honeycomb monolith, single porous structure and their combinations.

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

Implementation Option 1: An aerosol delivery system comprising

part in the form of a control housing containing

a first elongated tubular element having opposite ends, and

the source of energy placed in it; And

a part in the form of a cartridge body, containing

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

one end of the first and second ends is releasably engaged with one of the opposite ends of the part in the form of a control housing, and

the part in the form of a cartridge body further comprises a first device for generating an aerosol placed inside the second tubular element and made with the possibility of functional interaction with the energy source after engagement between one of the opposite ends of the part in the form of a control body and one end of the first and second ends of the part in the form of cartridge body, and

the other end of the first and second ends of the cartridge body portion is further configured as a mouth-engaging end if necessary, and

the cartridge body portion further comprises a second aerosol generating device within a second tubular member positioned between the first aerosol generating device and the mouth engaging end.

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

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

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

the first separating element is a heat-conducting or air-permeable element.

Embodiment 5: An aerosol delivery system according to any previous or subsequent embodiment of the present invention, or combinations thereof, wherein the first separating element is extended along a longitudinal axis between opposite ends to determine the thickness, and

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

Embodiment 6: An aerosol delivery system according to any previous or subsequent embodiment of the present invention, or combinations thereof, further comprising a second separating element positioned within the second tubular element between the second aerosol generating device and the mouth engaging end, wherein

the second separating element is a heat-conducting or air-permeable element.

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

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

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

the cartridge is configured to receive a second tubular element.

Embodiment 8: An aerosol delivery system according to any previous or subsequent embodiment of the present invention, or combinations thereof, wherein

the first aerosol generating device comprises a liquid reservoir disposed within the second tubular member and configured to receive a substance to be aerosolized used by the first aerosol generating device to generate a primary aerosol.

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

the substance to be aerosolized is a substance free of fragrances and acids.

Embodiment 10: An aerosol delivery system according to any previous or subsequent embodiment of the present invention, or combinations thereof, wherein

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

Embodiment 11: An aerosol delivery system according to any previous or subsequent embodiment of the present invention, or combinations thereof, wherein

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

at least one aerosol generating element is positioned to interact with heat and primary aerosol drawn through it towards the mouth end in response to suction applied to the mouth end in the cartridge body portion.

Embodiment 12: An aerosol delivery system according to any previous or subsequent embodiment of the present invention, or combinations thereof, wherein

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

Embodiment 13: An aerosol delivery system according to any previous or subsequent embodiment of the present invention, or combinations thereof, wherein

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

Embodiment 14: An aerosol delivery system according to any previous or subsequent embodiment of the present invention, or combinations thereof, wherein

at least one aerosol generating member of the second aerosol generating device is configured to interact with the primary aerosol and introduce an enhancing agent into the primary aerosol generated by the first aerosol generating device to form an improved aerosol drawn towards the mouth engaging end in response to suction applied to it.

Embodiment 15: An aerosol delivery system according to any previous or subsequent embodiment of the present invention, or combinations thereof, wherein

at least one aerosol generating element of the second aerosol generating device is configured to interact with the primary aerosol and remove heat from the primary aerosol generated by the first aerosol generating device to form a cooled aerosol drawn towards the mouth engaging end in response to an applied suction to it.

Embodiment 16: An aerosol delivery system comprising:

part in the form of a control housing containing

the first elongated tubular element having opposite ends, and placed in the source of energy;

a part in the form of a cartridge body, containing

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

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

the cartridge body part further comprises a first aerosol generation device placed inside the second tubular element and configured to be operatively interacted with the energy source after engagement between one of the opposite ends of the control body part and the first end of the cartridge body part,

the second end of the cartridge body part faces towards the mouth-engaging end of the aerosol delivery system; And

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

the second aerosol generating device is or releasably engaged with the cartridge body part or placed inside the second tubular element of the cartridge body part.

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

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

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

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

nicotine is made in the form of a free base, in a salt form, as a complex compound or a solvate.

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

elements for forming an aerosol additionally contain one or more fillers, binders, flavors and combinations thereof.

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

elements for the formation of an aerosol are treated with smoke.

Embodiment 21: An aerosol delivery system according to any previous or subsequent embodiment of the present invention, wherein

the second aerosol generating device is housed within the second tubular element of the cartridge body portion and comprises a plurality of aerosol generating elements in the form of spherical particles or tablets held in place by a first air-permeable separating element placed inside the second tubular element between the first aerosol generating device and a second aerosol generating device; and a second separating element between the second aerosol generating device and the mouth engaging end.

Embodiment 22: An aerosol delivery system according to any previous or subsequent embodiment of the present invention, wherein

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

Embodiment 23: A method for forming an aerosol supply system, comprising

engagement with the possibility of disengagement of one end of the first elongated tubular element with the first end of the second tubular element, and

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

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

the first aerosol generating device is operable with the power source after being engaged between one end of the control body part and the first end of the cartridge body part; And

inserting the second aerosol generating device within the second tubular element of the cartridge body portion between the first aerosol generating device and the second end of the second tubular element, wherein

the second end is opposite the first end and is formed as a mouth-engaging end.

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

said operation of engaging the second aerosol generating device with the cartridge body portion includes inserting the second aerosol generating device within the second tubular member of the cartridge body portion, between the first aerosol generating device and the second end of the second tubular member, wherein

the second end is opposite the first end and is formed as a mouth-engaging end.

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

inserting the second aerosol generating device within the second tubular element further comprises inserting at least one aerosol generating element, which at least partially forms the second aerosol generating device, into the second tubular element, wherein

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

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

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

the first separating element is a heat-conducting or air-permeable element.

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

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

the second separating element is a heat-conducting and air-permeable element.

Embodiment 28: A method according to any previous or subsequent embodiment of the present invention, or combinations thereof, wherein

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

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

the elongated tubular body is additionally capable of receiving at least one element for generating an aerosol and interacting with opposite end elements to contain at least one element for generating an aerosol, and

inserting the second aerosol generating device further includes inserting the cartridge inside the second tubular member of the cartridge body portion.

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

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

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

the second tubular element is made as a part in the form of a cartridge body and contains the first device for generating an aerosol placed in it,

the first aerosol generating device is operable with the power source after being engaged between one end of the control body part and the first end of the cartridge body part,

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

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

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

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

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

said operation of engagement of the second aerosol generating device with the cartridge body portion includes releasably engaging the second aerosol generating device with the cartridge body portion,

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

in which

the second aerosol generating device comprises a plurality of aerosol generating elements in the form of spherical particles or tablets held in place by a first breathable separating element between the first aerosol generating device and the second aerosol generating device and a second separating element between the second aerosol generating device and the cooperating with a mouth at the end.

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

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

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

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

nicotine is made in the form of a free base, in a salt form, as a complex compound or a solvate.

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

elements for forming an aerosol additionally contain one or more fillers, binders, flavors and combinations thereof.

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

elements for the formation of an aerosol are treated with smoke.

These and other features, aspects and advantages of the present invention will become apparent upon reading the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present invention comprises any combination of two, three, four or more of the aforementioned embodiments, as well as combinations of any two, three, four or more features or elements set forth in this disclosure, whether or not such features or elements are explicitly combined in the specific embodiment described here. This disclosure is intended to be read in its entirety such that any individual features or elements of the disclosed invention, in any of its various aspects and embodiments, are to be considered capable of being combined unless the context clearly indicates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

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

In FIG. 1 schematically shows an aerosol delivery device comprising a cartridge body and a control body, the cartridge body being shown in an exploded configuration and the control body being shown in an assembled configuration according to an exemplary aspect of the present invention;

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

In FIG. 3 schematically shows the cartridge housing of FIG. 1 implementing an additional aerosol generating device comprising one or more aerosol generating elements, in accordance with one aspect of the present invention.

In FIG. 4 schematically shows the additional aerosol generating device of FIG. 3 in the form of a cartridge containing one or more aerosol generating elements according to another aspect of the present invention;

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

In FIG. 6A is a schematic, assembled view of the carbon-based cartridge body of FIG. 5 according to an exemplary feature of the present invention;

In FIG. 6B schematically shows an assembled carbon-based cartridge body implementing an additional aerosol generating device, including one or more aerosol generating elements, in accordance with one aspect of the present invention.

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

In FIG. 8 is a sectional view of a second aerosol generating device releasably attached to an outer housing housing a first aerosol generating device according to an exemplary aspect of the present invention.

Detailed description of the preferred embodiments of the invention

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

As described hereinafter, features of the present invention are related to aerosol delivery systems. The aerosol delivery systems of the present invention use electrical energy to heat the material (in the preferred embodiment without burning the material to any significant extent) to form an inhalable substance; and the components of such systems are in product form, preferably compact enough to consider such systems as handheld devices. Thus, the use of components of the preferred aerosol delivery systems does not result in smoke generation in the sense that the aerosol originates predominantly from tobacco combustion or pyrolysis by-products, but rather, the use of these preferred systems results in the generation of vapors (including vapors within the aerosols, which may be considered as visible/invisible aerosols, which can be considered to be described as similar to smoke) arising from the evaporation or vaporization of certain components included therein. In carrying out the preferred features of the invention, the components of aerosol delivery systems can be characterized as electronic cigarettes, and most preferably these electronic cigarettes contain tobacco and/or tobacco-derived components, and therefore deliver tobacco-derived components in aerosol form.

The aerosol generating devices in certain preferred aerosol delivery systems are capable of providing many sensations (e.g., inhalation and exhalation rituals, flavor or aroma types, organoleptic effects, physical sensation, usage rituals, visual cues such as those provided by a visible aerosol, and the like. .) smoking of a cigarette, cigar or pipe, which occurs when tobacco is ignited and burned (and therefore when tobacco smoke is inhaled), without any significant degree of combustion of any of their components. For example, a user of the aerosol generating device of the present invention can hold and use the device in a very similar way to how a smoker would use a traditional type of smoking article, puffing at one end of the article to inhale the aerosol generated by the article, puffing at selected time intervals. etc.

The aerosol delivery systems of the present invention may also be characterized as suitable vapor generating articles, aerosol generating articles, or medicament delivery articles. Thus, such articles, systems, or devices may be adapted to deliver one or more substances (eg, flavoring agents, pharmaceutically active ingredients, peptides, protein fragments, and/or protein coats) in an inhalable form or condition. For example, respirable substances may be essentially in the form of a vapor (ie, a substance present in the gas phase at a temperature below its critical point). Alternatively, the respirable material may be in the form of an aerosol (ie, a suspension of fine solid particles or liquid droplets in a gas). For purposes of simplicity, the term "aerosol" as used herein is intended to describe vapors, gases, aerosols, and/or particulate matter in a form or type suitable for human inhalation, whether or not it is visible, and whether or not it has a form that might be thought to be like smoke.

The aerosol delivery systems of the present invention most preferably comprise some combination of an energy source (i.e., an electrical power source), at least one control component (e.g., means for driving, controlling, adjusting, and cutting off power for heat generation, for example, by controlling an electric current from an electrical power source to other components of the aerosol generating device), a heating element or a heat generation component (for example, an electrical resistance heating element and related components, commonly referred to as providing an "atomizer"), and the composition to be aerosolized substances (for example, usually a liquid capable of producing an aerosol when sufficient heat is applied, such as ingredients commonly referred to as "smoky juice", "e-liquid" and "e-juice"), and the area of the mouthpiece interacting with the end mouth or tip configured to puff the aerosol delivery system for inhaling aerosols (eg, at a specific air flow path through the aerosol generating device such that the generated aerosol can be drawn out therefrom by puffing).

More specific formats, configurations, and arrangements of article components within aerosol delivery systems of the present invention will be apparent in light of the further disclosure presented herein. In addition, the selection and location of the various components of the aerosol delivery system can be judged by considering commercially available electronic aerosol delivery devices, such as those representative items mentioned in the Background section of this specification.

According to certain aspects of the invention, the aerosol delivery devices of the present invention can, in use, be subjected to many of the physical effects experienced by a person using a traditional type of smoking article (eg, cigarettes, cigars, or pipes that are used by lighting and inhaling tobacco). For example, the user of the aerosol dispenser of the present invention can hold the article as a conventional type of smoking article, puffing at one end of the article to inhale the aerosol produced by the article, puffing at selected time intervals, and so on.

One such example of an aerosol delivery system 100 is illustrated in FIG. 1. In particular, in FIG. 1 is a partially exploded view of an aerosol delivery system 100 including a cartridge body 200 and a control body 300 (otherwise referred to herein as "cartridge body portion" and "control body portion", respectively). The cartridge body 200 and the control body 300 may be permanently or removably oriented or releasably engaged in an operable relationship. Various devices may be used to connect the cartridge body 200 to the driver body 300, resulting in a threaded engagement, a press fit engagement, an interference fit, a magnetic engagement, and the like. The aerosol delivery system 100 may be substantially rod-like, substantially tubular, or substantially cylindrical in some embodiments of the present invention with the cartridge body 200 and control body 300 assembled. As used herein, the term "tubular" refers to hollow elongated body, but is not limited to a certain cross-sectional shape or a certain external contour of the body. Those skilled in the art will also appreciate that in some cases, although not detailed here, the cartridge body 200 and control body 300 forming the aerosol delivery system 100 may be formed as a single, integral entity and may include components, features, and properties related to and disclosed in this disclosure.

In some instances, one or both of cartridge body 200 and control body 300 may be referred to as disposable (ie, as previously described as a single, non-detachable item) or reusable. For example, the reusable control housing 300 may have a replaceable battery or a rechargeable battery, and thus may be combined with any type of recharge technology, including connection to a conventional electrical outlet, connection to a car charger (i.e., lighter socket) and connection to a computer, for example, via a USB cable. Typically, an aerosol delivery system of the type disclosed herein comprises a battery or other source of electrical power to supply sufficient electrical current to implement various product features, such as powering a heater or heating element, powering control systems, powering indicators, and the like. The energy source can have various implementation options. In a preferred embodiment, the energy source is capable of supplying sufficient power to rapidly heat the heating element to generate an aerosol and to power the article through use for the required length of time. The energy source is preferably sized to fit comfortably within the aerosol delivery device/system so that the aerosol delivery device/system can be easily handled; and furthermore, the preferred energy source is light enough not to impair the desired smoking experience. In addition, in some cases, the cartridge body 200 may comprise a disposable cartridge, as disclosed, for example, in U.S. Published Application No. 2014/0060555 (Chang et al.), the contents of which are incorporated herein by reference in their entirety.

In FIG. 2 shows an exploded view of the control housing 300 of the aerosol supply system 100 according to another example. As shown, the control housing 300 may include a coupling device 302, an outer housing 304, a sealing element 306, an adhesive element 308 (for example, KAPTON® brand adhesive tape), a flow sensor 310 (for example, a puff sensor or pressure switch), a control component 312, a spacer 314, a power source 316 (e.g., a battery that can be rechargeable), a circuit board with an indicator 318 (e.g., with an LED), a connector circuit 320, and an end cover 322. Examples of power sources are described in the published application for US patent No. 2010/0028766 (Peckerar and others), the contents of which are fully incorporated into this application by reference.

With respect to flow sensor 310, specific current control components and other current control components, including various microcontrollers, sensors, and switches for aerosol delivery devices/systems, are described in, for example, US Pat. Nos. 4,735,217 (Gerth et al.); 4,947,874 (Brooks et al.); 5,372,148 (McCafferty et al.); 6,040,560 (Fleischhauer et al.); 7,040,314 (Nguyen et al.) and 8,205,622 (Pan); U.S. Patent Publication No. 2009/0230117 (Fernando et al.); 2014/0060554 (Collett et al.); and 2014/0270727 (Ampolini et al.), and US Patent Application No. 14/209191 filed March 13, 2014 (Henry et al.), the contents of which are hereby incorporated by reference.

In some cases, indicator 318 may include one or more LEDs. Indicator 318 may be in communication with control component 312 via connector circuit 320 and illuminate, for example, while a user is puffing on cartridge body 200 associated with coupler 302, as detected by flow sensor 310. The end cap 322 may be adapted to allow visibility of the illumination provided underneath by indicator 318. Accordingly, indicator 318 may be lit during use of the aerosol delivery system 100 to simulate the lit end of a smoking article. However, in other cases, the indicator 318 may be provided in different numbers and shapes, and may even be an opening in the outer housing (for example, to release sound when such indicators are present). Additional specific types of components providing visual information or indicators, such as LED components, as well as their configuration and use, are described in US Pat. No. 5,154,192 (Sprinkel et al.); 8,499,766 (Newton) and 8,539,959 (Scatterday); and US patent application no. No. 14/173266, registered February 5, 2014 (Sears et al.); the contents of which are incorporated into this application by reference.

Additional features, controls, or components that may be included in the aerosol delivery devices and systems of the present invention are described in US Pat. Nos. 5,967,148 (Harris et al.); 5,934,289 (Watkins et al.); No. 5,954,979 (Counts et al.); 6,040,560 (Fleischhauer et al.); 7,726,320 (Robinson et al.); 8,365,742(Hon); 8,402,976 and 8,689,804 (Fernando et al.); in U.S. Published Applications 2013/0192623 (Tucker et al.); 2013/0298905 (Leven et al.); 2013/0180553 (Kim et al.) and 2014/0000638 (Sebastian et al.); and US Published Applications No. 2014/0261495 (Novak, III et al.) and 2014/0261408 (DePiano et al.); the contents of which are incorporated herein by reference in their entirety.

Returning to FIG. 1, the cartridge body 200 is shown in an exploded configuration. As shown, the cartridge body 200 may include a base shipping plug 202, a base 204, a control clip 206, an electronic control component 208, a flow tube 210, an atomizer 212, a reservoir substrate 214, an outer shell 216, a sticker 218, a mouthpiece 220, and a shipping plug 222. mouthpiece according to an exemplary embodiment of the present invention. The base 204 may be associated with the first end of the outer shell 216, and the mouthpiece 220 may be associated with the opposite second end of the outer shell 216 to enclose the remaining components of the cartridge body 200. The base 204 may be configured to releasably engage with the coupling device 302 of the control body 300. In some instances, the base 204 may include anti-rotation means that substantially prevent relative rotation between the cartridge body and the control body, as disclosed in U.S. Published Application No. 2014/0261495 (Novac, III et al.), the contents of which are hereby incorporated by reference in their entirety. Various characteristic connectors for upstream and downstream electronic cigarette components have been formulated in the patent literature and used to manufacture commercially available electronic cigarettes. For example, specific types of connectors and components for electronic cigarettes are described in U.S. Published Application No. 2014/0261495 (Novac, III et al.) and U.S. Patent Application No. No. 14/170,838, registered February 3, 2014 (Bless et al.); the contents of which are incorporated into this application by reference.

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

The orientation of the components within either the control housing or the cartridge housing of the aerosol delivery device/system, or both housings, may be different. As certain features of the invention, the composition to be aerosolized may be placed near one end of the complete article (e.g., within a cartridge body, which under certain circumstances may be replaceable and disposable), which may be configured to be placed relatively close to the user's mouth to maximize aerosol delivery. user. However, other configurations are not excluded. Typically, the heating element may be placed close enough to the composition to be aerosolized such that the heat from the heating element is capable of nebulizing the substance to be aerosolized (and/or one or more fragrances, medicaments, etc., which may likewise be provided to deliver user) and form an aerosol for delivery to the user. When the composition to be aerosolized is heated by the heating element, an aerosol is formed, released or produced in a physical form suitable for inhalation by the consumer. It should be noted that the foregoing terms are intended to be interchangeable, so that the use of the terms "issue, release, issue or issued" is the same as "form or produce, form or produce, form or produce, and educated or produced". In particular, the respirable substance is released as a vapor or an aerosol or a mixture thereof. In addition, the choice of various components of the aerosol dispenser can be evaluated after consideration of commercially available electronic aerosol dispensers such as the representative articles mentioned above in this specification.

The atomizer (i.e., aerosol generating device) 212 may include a first heating element clip 234a and a second heating element clip 234b, a liquid transfer element 238, and a heating element 240. In this regard, the reservoir and/or reservoir substrate 214 may be configured with the ability to contain the composition to be aerosolized. The composition to be aerosolized, also referred to as the composition to be vaporised, may contain a variety of components in various aspects. Such components may include, by way of example, any polyhydric alcohol (eg, glycerol, propylene glycol, or mixtures thereof), nicotine, tobacco, tobacco infusion, water, flavors, and combinations thereof.

The composition to be aerosolized or the composition to be vaporized may be different. Most preferably, a composition to be aerosolized consists of a combination or mixture of various ingredients or components. The selection of certain components of the material to be aerosolized and the relative amount of these components used can be varied to control the overall chemical composition of the base aerosol produced by the aerosol generating device(s). Of particular interest are aerosolizable compositions which can be characterized as being generally liquid in nature. For example, exemplary, typically liquid, aerosolizable compositions may be in the form of liquid solutions, viscous gels, mixtures of soluble components, or liquids containing suspended or dispersed components. Typical aerosolizable compositions are capable of volatilization when exposed to heat under the same conditions as when using the aerosol generating device(s) that are characteristic of the present invention; and are therefore capable of producing respirable vapors and aerosols.

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

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

The composition to be aerosolized may also contain so-called "aerosol-forming materials". In some instances, such materials may be capable of producing a visible (or non-visible) aerosol when evaporated under the influence of heat under conditions encountered during normal operation of the aerosol generating device(s) that are characteristic of the present invention. Such aerosol-forming materials contain various polyols or polyhydric alcohols (eg, glycerol, propylene glycol, and mixtures thereof). Features of the present invention also include components of the aerosolized substance, which can be characterized as water, saline, moisture or aqueous liquid. During normal operating conditions of a particular aerosol generating device(s), the water contained within that aerosol generating device(s) may be evaporated to form a generated aerosol component. Also, for the purposes of the present invention, the water present within the composition to be aerosolized can be considered an aerosol-forming material.

A wide variety of optional flavoring agents or materials may be used to modify the sensory character or nature of the elongated base aerosol produced by the aerosol delivery system of the present invention. For example, such optional flavoring agents can be used within the composition or substance to be aerosolized to modify the flavor, odor, and organoleptic properties of the aerosol. Certain flavoring agents may be obtained from sources other than tobacco. Exemplary fragrances may be natural or artificial in nature and may be used as fragrance concentrates or packs.

Exemplary flavors include vanillin, ethyl vanillin, cream, tea, coffee, fruits (eg apple, cherry, strawberry, peach and citrus flavors including lime and lemon), maple, menthol, mint, peppermint, spearmint , wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, croton wood, cocoa, licorice, and flavors and flavor packages of the type and character traditionally used to flavor cigarettes , cigars and pipe tobacco. Molasses such as high fructose corn syrup can also be used. Certain flavoring agents may be incorporated into the aerosol forming materials prior to the formation of the final mixture of the substance to be aerosolized (e.g., certain water-soluble flavoring agents may be incorporated into water, menthol may be incorporated into propylene glycol, and certain complex flavor packages may be incorporated into propylene glycol) . However, according to certain features of the present invention, the composition to be aerosolized may not contain any fragrance, fragrance characteristics or additives.

Compositions to be aerosolized may also include ingredients exhibiting acidic or basic characteristics (eg, organic acids, ammonium salts, or organic amines). For example, certain organic acids (e.g., levulinic acid, succinic acid, lactic acid, and pyruvic acid) may be formulated into an aerosolized substance comprising nicotine, preferably in amounts up to equimolar (based on total organic acid content) with nicotine. For example, the substance to be aerosolized may contain from about 0.1 to about 0.5 moles of levulinic acid per mole of nicotine, from about 0.1 to about 0.5 moles of pyruvic acid per mole of nicotine, from about 0.1 to about 0.5 moles of lactic acid per mole of nicotine, or a combination thereof, up to a concentration at which the total amount of organic acid present is equimolar to the total amount of nicotine present in the substance to be aerosolized. However, according to certain features of the present invention, the composition to be aerosolized may not have any acidic (or basic) characteristic or additives.

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

Specific types of components and formulations to be aerosolized substances are also formulated and characterized in US patent No. 7,217,320 (Robinson and others) and patent publications No. 2013/0008457 (Zheng and others); 2013/0213417 (Chong et al.) and 2014/0060554 (Collett et al.), the contents of which are incorporated herein by reference. Other aerosolizable substances that may be used include the aerosolizable substances that were included in R. J. Reynolds Vapor Company, Lorillard Technologies BLUTM product, Mistic Ecigs MISTIC MENTHOL product, and Creative Ltd. VYPE CN product. Also desirable are so-called "smoky juices" for electronic cigarettes manufactured by Johnson Creek Enterprises LLC.

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

The substrate 214 of the tank may contain many layers of non-woven fibers, made in the form of a tube, surrounding the inside of the outer shell 216 of the housing 200 of the cartridge. Thus, liquid components, for example, can be stored by sorption in the substrate 214 of the tank. The reservoir substrate 214 is fluidly connected to the liquid transfer element 238 . The liquid transfer element 238 may be configured to transfer liquid (ie, the compositions to be aerosolized) from the reservoir substrate 214 to the heating element 240 via capillarity. Representative types of substrates, reservoirs, or other components to support the composition to be aerosolized are described in US Pat. No. 8,528,569 (Newton); US Published Applications No. 2014/0261487 (Chapman et al.) and 2015/0059780 (Davis et al.); and US Patent Application No. 14/170,838 filed Feb. 3, 2014 (Bless et al.); the contents of which are incorporated into this application by reference. In addition, various capillary materials, and the configuration and operation of these capillary materials within certain types of electronic cigarettes, are described in US Published Application No. 2014/0209105 (Sears et al.); the contents of which are incorporated into this application by reference.

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

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

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

During use, the user may puff on the mouthpiece or on the mouth end 220 of the cartridge body 200 of the aerosol delivery system 100. In this case, air may be drawn in through an opening in the control housing 300 and/or in the cartridge housing 200. For example, in one case, an opening may be formed between the coupling device 302 and the outer shell 304 of the control housing 300, as described in US Published Application No. 2014/0261408 to DePiano et al. However, in other embodiments of the present invention, the air flow may be obtained through other parts of the aerosol supply device/system 100. As noted above, according to certain aspects of the invention, the cartridge body 200 may include a flow tube 210. The flow tube 210 may be configured to direct the flow of air received from the control body 300 to the heating element 240 of the atomizer 212.

A sensor in the aerosol delivery device/system 100 (eg, a puff or flow sensor in the control housing 300) is capable of sensing a puff. More generally, a sensor or detector may be implemented to control the supply of electrical power to heating element 240 as needed to generate an aerosol (eg, puff during use). Also, for example, a course of action or method is provided for turning off the power supply to the heating element 240 when it is not necessary to generate aerosol during use, and for turning on the power supply to activate the start of heat generation by the heating element 240 during a puff. Additional specific types of sensing and sensing devices, their structures and configurations, their components, and their general methods of operation are described in US Pat. Nos. 5,261,424 (Sprinkel, Jr.); 5,372,148 (McCafferty et al.); and in PCT application WO 2010/003480 (Fick); the contents of which are incorporated herein by reference in their entirety. When sensing a puff, control housing 300 is able to direct current to heating element 240 through a circuit comprising first heating element terminal 234a and second heating element terminal 234b. Accordingly, the heating element 240 is capable of vaporizing the composition to be aerosolized directed towards the aerosolization zone from the reservoir substrate 214 by the liquid transfer element 238 . Thus, the mouthpiece 220 may allow air and trapped vapor (ie, the components of the composition to be aerosolized in a respirable, eg, aerosol form) to pass from the cartridge body 200 to a puffing user. Various other details regarding components that may be included in cartridge body 200 are provided, for example, in US Published Application No. 2014/0261495 (Novac, III et al.), the contents of which are hereby incorporated by reference in their entirety.

Various components of the aerosol delivery device/system may be selected from those described in the state of the art and commercially available. For example, reference is made to a reservoir and heating element system for controlled delivery of many aerosolizable materials in an electronic smoking article disclosed in U.S. Published Application No. 2014/0000638 (Sebastian et al.), the contents of which are incorporated herein in their entirety. application by reference. In addition, note that shown in Fig. 1 parts of the cartridge body 200 are optional. In this regard, by way of example, the cartridge body 200 may, in some cases, not necessarily include the flow tube 210, the clip 206 of the control component 206, and/or the electronic control component 208.

One specific feature according to the present invention is illustrated, for example, in FIG. 3. In such cases, the cartridge body 200 may further comprise a second aerosol generating device 400 (the atomizer 212 is referred to as the "first aerosol generating device") placed in the outer shell 216 longitudinally between the atomizer 212 and the mouthpiece or mouth engaging end 220 body 200 of the cartridge. In accordance with certain aspects of the present invention, the second aerosol generation device 400 is typically porous or otherwise capable of passing air therethrough. In certain instances, the second aerosol generating device 400 may comprise one or more aerosol generating elements 425, which may comprise at least one or a plurality of pellets or spherical particles or other appropriate elements or combinations thereof. In some instances, at least one or a plurality of pellets or spherical particles or other suitable elements or combinations thereof forming the aerosol generating element(s) 425 may optionally be coaxially surrounded by a typically tubular heat transfer element and/or surrounded or otherwise lined. insulation (for example, a non-woven mat or a layer of glass threads or fibers) or other suitable material (not shown).

It is believed that the overall configuration of the second aerosol generation device 400 within the cartridge body 200 of the aerosol delivery device/system 100 is generally cylindrical. Specific preferred spherical particles or other entities may be formed from a formulation containing tobacco (e.g., particulate tobacco), tobacco components, and/or materials that are otherwise derived from tobacco (e.g., tobacco extracts such as aqueous tobacco extracts, or nicotine derived from tobacco, including pharmaceutical grade nicotine). The spherical particles most preferably contain flavorants and a visible or invisible aerosol-forming material (eg, glycerin or other material that produces a visible smoke-like vapor). Thus, the spherical particle components are preferably configured to act as support components for volatile flavors, vapor, moisture or other liquid(s) generating materials, and/or aerosol forming materials carried by them. In accordance with certain aspects of the invention, the aerosol generating element(s) 425 may include or otherwise comprise or be formed as, for example, marumarized tobacco spherical particles of various shapes and sizes, a monolith of bonded (e.g., sintered) spherical tobacco particles forms; porous monolith; single porous structure; honeycomb monolith; a single piece of porous material; extruded tobacco spherical particles; spherical particles of porous material containing tobacco extract (for example, calcium carbonate, ceramics, etc.); scraps of reconstituted tobacco; cuts of ground tobacco; extruded rods of various materials (including hollow cylinders and slotted rods) containing tobacco flavors; shavings, granules, capsules and/or microcapsules of various materials containing tobacco flavors or other substances, in liquid or other form; and their combinations or the result of their processing.

Generally, as used herein, the terms "tablets" and "spherical particles" mean spherical particles, tablets, or other discrete small units or portions that may contain (in addition to elements otherwise disclosed herein), for example, carbonaceous pieces, extruded carbonaceous pieces , cut into tablets, spherical ceramic particles, marumerized tobacco pieces, and the like, or combinations thereof. For example, granules, tablets, or spherical particles can typically be cylindrical or spherical extruded or compressed granules, tablets, or spherical particles, consisting of a moistened mixture or liquid solution of ground tobacco leaf, excipients (for example, granulated calcium carbonate), flavoring agents, forming a visible aerosol of materials and binders (eg, carboxymethyl cellulose) that is shaped, cut, or extruded to the desired size and shape, and then dried to maintain the desired shape. However, such "tablets" or "spherical particles" may contain any suitable elements, or combinations of elements, that implement the preferred features disclosed here. For example, some or all of the spherical particles or tablets may be heat-sensitive spherical capsules such that when incorporated into an aerosol forming element and subjected to heat, their disruption or decomposition causes the release of glycerol, propylene glycol, water, saline, tobacco flavors. and/or nicotine or other substances or additives. In addition, the spherical particles may contain ceramic or absorbent clay or silica or activated carbon to contain and release the aerosol form. In addition, according to certain aspects of the invention, the spherical particles/tablets may contain a thermally conductive material, such as, for example, thermally conductive graphite, thermally conductive ceramic, metal, tobacco, loose on foil, metal or other suitable material, impregnated with appropriate aerosol generating substances, such as glycerin and flavor(s), or a suitable cast sheet material which is suitably formed into the desired spherical/tablet particles.

In one specific example, the spherical particles/tablets (particles) may be composed, by weight, of from about 15% to about 60% finely ground tobacco particles (e.g., a mixture of Oriental Burley-type tobacco and flue-cured tobacco, essentially all tobacco Oriental, essentially all Burley tobacco, or essentially all fire-cured tobacco), about 15% to about 60% finely ground calcium carbonate particles (or finely ground clay or ceramic particles), from about 10% to about 50% glycerin (and minor flavorings if necessary), about 0.25% to about 15% binder (preferably carboxymethyl cellulose, guar gum, potassium, or ammonium alginate), and about 15% to about 50% water. In another example, the spherical particles/tablets (particles) may be composed of about 30% finely ground tobacco particles (e.g., mixture of Oriental Burley tobacco and flue-cured tobacco, essentially all Oriental tobacco, essentially all Burley tobacco, or essentially all fire-cured tobacco), about 30% finely ground calcium carbonate particles (or finely ground clay or ceramic particles), about 15% glycerol (and minor flavors if necessary), about 1% binder (preferably carboxymethyl cellulose, guar gum, potassium or ammonium alginate), and about 25% water. In such examples, the particles may be compressed to retain glycerol and upon compression may form a porous matrix that facilitates movement of the aerosol generating components to maintain efficient aerosol generation. The manner in which the aerosol-forming material contacts the substrate material may vary. The aerosol-forming material may be applied to the formed material, may be incorporated into processed materials during the manufacture of those materials, or may be endogenous to the material. An aerosol-forming material, such as glycerol, may be dissolved or dispersed in an aqueous liquid or other suitable solvent or carrier liquid and sprayed onto the support material. See, for example, US Published Applications No. 2005/0066986 (Nestor et al.) and 2012/0067360 (Conner et al.); the contents of which are incorporated into this application by reference. The calcium carbonate or other inorganic filler aids in creating pores within the particles and may also work to absorb heat, which in some cases may limit or otherwise prevent burning of components to form an aerosol, and assist and promote aerosol formation. See also, for example, the types of materials described in US patent No. 5,105,831 (Banerjee and others) and published applications for US patent No. 2004/0173229 (Crooks and others); 2011/0271971 Conner et al.); and 2012/0042885 (Stone et al.); the contents of which are incorporated herein by reference in their entirety.

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

The composition of the compositions to be aerosolized for the first aerosol generating device and the composition of the aerosol generating elements for the second aerosol generating device are preferably chosen to complement each other to form the desired perception process. For example, in certain embodiments of the present invention, the nicotine content of the aerosolizable compositions and aerosol generating elements is chosen such that any or both of the aerosolizable compositions and aerosol generating elements may contain nicotine or nicotine compounds or may be considered as essentially or absolutely free of nicotine or nicotine compounds. In other words, all of the nicotine content may be within the aerosol generating elements, or all of the nicotine content may be in the compositions to be aerosolized, or both compositions may include nicotine in some form.

According to certain aspects of the invention, where the aerosol generating elements 425 are, for example, spherical particles or tablets molded or extruded from the various types of materials mentioned above (i.e., spherical graphite particle containing tobacco liquor and glycerin), moistened or otherwise treated before drying, they can be rolled, for example, between adjacent rolls to smooth the shape of the respective spherical particles/tablets. In some instances, the various types of materials mentioned above may be extruded in the form of filamentous fibers, which fibers may be assembled to form a cylindrical rod or other material of suitable shape (i.e., sized to the spherical particles/tablets used to form otherwise an aerosol generating segment) for application in the second aerosol generating device 400. After drying, the flattened spheroids/tablets may then be ground or otherwise processed to form, for example, fibers, flakes, or other filler configuration that is flat or contains a flat segment that inhibits or prevents rolling. Any random configurations resulting from the grinding process may be sufficient. In such cases, the flattened and crushed spherical/tablet particles can then be incorporated into the aerosol generating element(s) 425 and their irregular or random configurations can support, for example, a plurality of intermediate air spaces throughout the aerosol generating element(s) 425 , and the intermediate air spaces can, in turn, support heat exchange with individual objects within the element (elements) 425 to form an aerosol. Thus, heating the air in the intervening spaces within the second aerosol generating device 400 may expose the heat from the heating element 240 to most of the aerosol generating element(s) 425 and thus result in increased or otherwise improved heating of the element(s). 425 to form an aerosol. In other cases, the heat and primary aerosol (i.e., a combination of the two) generated by the heating element 240/atomizer 212 are directed through the porous matrix formed by the aerosol forming element(s) 425, with the heated vapor passing through the porous element(s) ) 425 to form an aerosol and heating them, support, for example, elution (i.e., extraction of liquid, fluid, or particles; steam distillation; additives) from the element(s) to form an aerosol into the primary aerosol, or otherwise support the enhancer being taken up by, transferred to, reacting with, or otherwise interacting with the primary aerosol, the primary aerosol. The interaction between the enhancer and the primary aerosol may, for example, change or transform the primary aerosol, mix the enhancer with the primary aerosol to form an improved aerosol or aerosol mixture, or facilitate a reaction to form a diverse aerosol. In such cases, the increased pore space within the aerosol generating element(s) 425 can support this interaction process through the second aerosol generating device 400.

According to certain aspects of the invention, the spherical particles/tablets may be formed from a tobacco material cast on a foil/paper laminate. More specifically, the tobacco material may be, for example, a liquid solution containing reconstituted tobacco, glycerin and a binder. Such tobacco material is described, for example, in US Pat. No. 5,101,839 (Jacob et al.) and US Patent Application No. 2010/0186757 (Crooks et al.), the contents of which are incorporated herein by reference. In addition, the liquid solution may contain granular inorganic material (ie, calcium carbonate). The liquid solution is cast onto a foil/paper laminate such as described in, for example, US Pat. No. 8,678,013 (Crooks et al.) and US Pat. the assembled cast sheet product is then dried, for example, by applying heat (ie, hot air, microwave drying, etc.). The paper may, for example, have a certain porosity or texture to promote close contact and interaction with the liquid solution, for example, in direct contact between the liquid solution and the foil. However, the feature presented here and taken as an example does not prevent the tobacco material (ie, liquid solution) from being cast directly onto metal foil or other suitable thin film heat conductor. After being molded onto the laminate, the dried curtain sheet (i.e., foil/paper/tobacco type material) may be shredded, cut into pieces, or otherwise divided into a plurality of elements of a portion of the curtain sheet, each such element preferably comprising a portion tobacco material (i.e., substrate) intimately interacting with a part of the paper element, which, in turn, intimately interacts with a part of the foil element in a foil/paper laminate. The plurality of elements of the cast sheet portion may then be included in the aerosol generating element(s) 425 forming the second aerosol generating device 400.

Those skilled in the art will appreciate that, under some circumstances, the elements in the form of a cast sheet portion included in the aerosol forming element(s) 425 are capable of cooperating to promote improved heat transfer to the tobacco material forming part of these elements of the cast sheet portion, or otherwise to adjoining elements. In more detail, in some instances, heat transfer from heating element 240 to the tobacco material included in aerosol generating element(s) 425 may be limited along any immediate interface therebetween, with the thermally conductive tape forming an additional conduit for thermal conduction from heating element 240 for the purpose of heating the external elements included in the aerosol generating element(s) 425 and any aerosol generating element(s) in contact therewith. In embodiments having elements as part of the cast sheet included in the aerosol generating element(s) 425, the thermally conductive portions of the foil element associated with the elements as part of the cast sheet may form, for example, a plurality of additional heat conduction paths. Thus, the elements as part of the cast sheet used as all or part of the aerosol generating element(s) 425 can provide additional thermally conductive elements interspersed throughout the aerosol generating element(s) 425 within the second aerosol generating device 400, for thereby enhancing or otherwise improving heat transfer towards and between the aerosol generating elements. In implementing such a feature, it may be further advantageous to shred or process a support material, for example, in a coated tobacco leaf support material, to form a support enclosed within certain types of cigarettes marketed under the brand name "Eclipse" by R. J. Reynolds Tobacco Company" as disclosed, for example, in US Pat. No. 5,469,871 (Barnes et al.).

Tablets or other elements may have smooth, regular external shapes (eg, sphere, cylinder, oval surfaces, etc.) and/or they may have irregular external shapes (eg, crushed parts, flakes, etc.). The aerosol generating element(s) 425, individually or in combination, may be generally cylindrical in shape within the second aerosol generating device 400, and may in some instances include a plurality of from about 800 to about 1200 generally spherical spherical particles, each which has an average or nominal diameter of from about 0.05 mm to about 4 mm (i.e., about 1 mm ³ by volume, in one example), and the spherical particles/tablets collectively weigh from about 450 mg to about 750 mg (eg 600 mg ± 25% in one example).

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

The aerosol generating elements may be selected to have a relatively uniform average diameter, or a range of aerosol generating elements sizes may be included in the second aerosol generating device 400. When using different size ranges in the same device, elements of different sizes may be placed in a range or in layers within the second aerosol generating device 400, or elements of different sizes may be randomly mixed within the aerosol generating device 400. While not bound by any particular theory of operation, the use of different sizes of aerosol generating elements in the same aerosol generating device 400 can provide beneficial changes in device pressure drop and/or provide advantageous sensory performance based on different evaporation rates. provided by elements of different sizes.

In a preferred embodiment of the present invention, a sufficient amount of spherical particles is loaded into the second aerosol generator 400 to provide at least about 95 percent of the maximum load when using spherical particles and/or other suitable elements. It is advantageous to avoid large open pockets within the aerosol generating device 400, which would allow air to pass through the aerosol generating device without substantially interacting with the aerosol generating elements 425.

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

The atomizer or first aerosol generating device 212 and the second aerosol generating device 400 may be physically separated from each other and/or comprise discrete units or segments within the cartridge body 200. In some instances, as shown, these segments may be positioned/positioned such that the downstream end (toward the mouthpiece or mouth end 220 of cartridge body 200) of the atomizer or first aerosol generating device 212 is adjacent to the downstream end upstream end of the second segment 400 to generate an aerosol (ie with the rear surface of the element (elements) 425 to form an aerosol). Thus, the atomizer or first aerosol generating device 212 and the second aerosol generating segment 400 may be axisymmetrically oriented in a sequential end-to-end arrangement, and in some cases adjacent to or abutting each other. For example, in some cases, although they are physically discrete and installed downstream of the atomizer or first aerosol generating device 212, it may be desirable for the aerosol generating element(s) 425 of the second aerosol generating device 400 to be in physical contact with the heating element 240. located downstream end of the atomizer or first device 212 for generating aerosol. Alternatively, these segments 212, 400 may be slightly spaced apart such that their respective ends or components 240, 425 are not necessarily in physical contact with the other (ie, to prevent burning). Those skilled in the art will appreciate that, in some embodiments, the second aerosol generating device 400 may comprise more than one section or portion of the aerosol generating element(s) 425.

In some cases, an additional segment, spacer element, or separating element (otherwise referred to here as the "first separating element") acting as a spacer or screen (see, for example, element 450 in Fig. 3), can be installed generally perpendicular the longitudinal axis of the cartridge body 200, wherein the first spacer 450 may provide for the physical separation of the two segments 212, 400 while still maintaining a thermally conductive relationship between them in some cases. The first separation element 450 may not be thermally conductive in some cases, and in other cases the first separation element 450 may not be electrically conductive. Thus, the first spacer element 450 may, but need not, be thermally conductive and/or positioned to conduct heat from the atomizer heating element 240/first aerosol generating device 212 to the second aerosol generating device 400, wherein the element(s) 425 to form an aerosol may be sensitive to heat and/or an accompanying primary aerosol to form a secondary aerosol. In addition, in some cases, the first separation element 450 may be breathable or otherwise capable of passing air flow through it, so that the primary aerosol generated by the atomizer/first aerosol generating device 400 can pass through it in a downstream direction. The first spacer element 450 may thus be configured and/or positioned to support the aerosol generating element(s) 425 within the second aerosol generating device 400 and separate from the atomizer/first aerosol generating device 212. In other cases, the first separating element 450 may be configured as a spacer (i.e., extending longitudinally along the thickness determination cartridge body 200) to separate the aerosol generating element(s) 425 from the atomizer/first device heating element 240 212 to form an aerosol, for example, to minimize or prevent scorching or burning by heat from the heating element 240 of element(s) 4125 to form an aerosol (ie, spherical particles). In some cases, the first separation element 450 may also be configured as an insulator (ie, electrically non-conductive) to prevent the heating element 240 from shorting out if there is contact therebetween.

Typically, the first spacer 450 is generally cylindrical or disc-shaped in shape and in one piece, and is breathable to allow drawn air to pass through. The first separation element 450 may be thermally conductive in nature, so that the heat generated by the heating element 240 can be easily transferred to the second aerosol generating device 400. The length (thickness) of the first spacer 450 can vary, and typically ranges from less than about 1 mm to about 10 mm. In some cases, the relative longitudinal placement of the first spacer element 450 within the outer shell 216 leaves a gap between the heating element 240 and the interface between the first spacer element 450 and the aerosol generating element(s) 425 of about 1 mm to about 20 mm (i.e., .7 mm in one example). Typically, the first spacer 450 is made of a heat resistant material such as porous ceramic, porous graphite material, metal (i.e., stainless steel, brass, copper, etc.) cell or shield, high heat resistant plastic, and the like. In some cases, the first spacer element 450 may, for example, include longitudinally elongated air ducts formed during design/manufacturing, drilled through it, or otherwise molded, extruded, printed (i.e., representing a three-dimensional printed element obtained by a three-dimensional printer ), or made in the form of a spacer element during its production. If desired, the first separation element 450 may contain catalytic materials, for example, materials including ions or oxides of cerium or copper, or oxides and/or salts of cerium and copper ions. See, for example, U.S. Patent Nos. 8,469,035 and 8,617,263 (Banerjee et al.) and US Published Application No. 2007/0215168 (Banerjee et al.), the contents of which are hereby incorporated by reference in their entirety.

In cases where the aerosol generating element(s) 425 are surrounded by an insulating layer, a layer of thermally conductive material (eg, a layer or tape composed of metal foil) may be provided therebetween (not shown). Thus, the representative aerosol generating element(s) 425 comprises a plurality of tablets and/or other suitable elements that may be surrounded along its length by a layer of metal foil strip. A typical metal foil is, for example, aluminum foil with a thickness of from about 0.01 mm to about 0.05 mm. In the preferred embodiment of the present invention, the metal foil is stretched along the entire length of the outer coaxial surface of the element(s) 425 to form an aerosol; and preferably, the metal foil extends over (ie, at least partially overlaps) the first spacer element 450. The thermally conductive material may be provided by means other than the use of metal foil. For example, the metal foil layer may be replaced by a metal mesh or screen. Alternatively, the metal foil may be replaced by a thermally conductive fabric, such as a layer or sheet of graphite fibers or thermally conductive ceramic fibers. Alternatively, the thermally conductive material may be provided by applying a thermally conductive ink, such as an ink or paint coating that contains metal particles, graphitized fibers, thermally conductive ceramic material particles, and the like.

In FIG. 7 shows an example of yet another embodiment of a second aerosol generating device 400 placed within an outer shell or tubular member 216 (downstream of the first aerosol generating device 212, which is not shown). As shown, the aerosol generating elements 425 are positioned between spacer elements 450 and 475, which are designed to hold the aerosol generating elements 425 in place and allow air flow through them. As previously noted, the spacer members 450 and 475 may be porous (eg, in the form of honeycomb screens or perforated metal plates) with pore sizes selected to retain the aerosol generating members 425 within the second aerosol generating device 400.

As shown, the second aerosol generating device 400 may further comprise a separate aerosol generating element housing 460 in the form of, for example, a tubular housing with an open end facing the mouthpiece 220, which, as shown, can engage with the open end of the tubular housing and may be attached to it by a press fit or other known means. The body 460 may include an end 470 opposite the mouthpiece 220, which, as shown, may be perforated to allow air flow therethrough. Housing 460 may be made from any suitable material, including metal (eg, stainless steel) or plastic. The spacers 450 and 475 may be press-fit or otherwise engaged with the body 460, and the spacer 475 closest to the mouthpiece 220 may be attached to the mouthpiece if desired. In certain embodiments of the present invention, spacer members 450 and 475 are inserted into housing 460 during the molding process that forms the housing. The structure according to Fig. 7 is particularly well suited to embodiments of the invention where the second aerosol generating device 400 is designed to be permanently attached to the rest of the cartridge body 200 rather than being in the form of a removable or disposable device.

Alternatively, in those embodiments of the present invention where the second aerosol generating device 400 is adapted to be removed from the cartridge body 200 as a separate unit, the construction of FIG. 8. As shown, in the embodiment of FIG. 8, the second aerosol generating device 400 is formed as a separate unit with a separate housing body 520 that is connected (for example, by pleating or other means) to the first connector 540. The housing body 520 and the first connector 540 together form a cavity for the elements 425 to form aerosol. As in the embodiment of FIG. 7, the aerosol generating elements 425 are positioned between spacer elements 450 and 475, which are designed to hold the aerosol generating elements 425 in place and allow air flow through them. Similar to the embodiment of FIG. 7, spacers 450 and 475 may be press-fit or otherwise engaged with surrounding portions of first connector 540 or housing body 520, respectively, and may be inserted into these surrounding portions during the pressing process. The downstream spacer 475 is also attached to the mouthpiece 220, if desired.

The first connector 540 of the second aerosol generating device 400 is adapted to engage with a second connector 560 that is attached (e.g., by press fit or other means) to the outer casing or tubular member 216 housing the first aerosol generating device 212 (not shown) . The second connector 560 has an end facing the first connector 540 that allows the user to releasably attach the second aerosol generating device 400 to the cartridge body 200, for example, by means of a threaded engagement or other means of connection. As shown, the second connector 560 is porous to allow airflow from the first aerosol generating device 212 to enter the second aerosol generating device 400. The second aerosol generating device 400 of this embodiment is co-engaged with the mouthpiece 220 in a manner similar to FIG. 7.

According to certain aspects of the invention, another spacer element or another spacer (otherwise referred to here as the "second spacer") acting as a spacer or screen (see, for example, element 475 in Fig. 3) can be installed generally perpendicular the longitudinal axis of the cartridge body 200, wherein the second separating element 475 may provide for physically separating the second aerosol generating device 400 from the mouthpiece or mouth end 220 of the cartridge body 200. Thus, the second spacer 475 may optionally be thermally conductive and/or thermally conductive from the second aerosol generating device 400 and through the mouthpiece or through the mouth end 220 of the cartridge body 200. However, the second spacer 475 may be breathable or otherwise capable of passing through it such that the primary aerosol generated by the atomizer/first aerosol generating device 212 and/or the secondary aerosol generated by the second aerosol generating device 400 may pass through them in a downstream direction and through the mouthpiece, or through the mouth end 220 of the cartridge body 200. Thus, the second spacer element 475 may also be configured and/or positioned to support the aerosol generating element(s) 425 within the second aerosol generating device 400 without losing any aerosol generating element(s) through the mouthpiece or cooperating mouth end 220 of cartridge body 200.

In accordance with certain aspects of the invention, as an alternative to discrete first and second spacer elements 450, 475 provided in addition to the aerosol generating element(s) 425, the second aerosol generating device 400 may comprise a cartridge 500 (see, for example, FIG. 4) having an elongated tubular body 525 and opposing end members 550, 575, each of the end members 550, 575 may be thermally conductive and/or breathable in the same manner as the first and second spacer members 450, 475. Thus, the elongated tubular body 525 may be further configured to receive aerosol generating element(s) 425 and interact with opposing end elements 550, 575 to contain aerosol generating element(s) 425. The assembled cartridge 500 can thus be configured to be block-formed (forming the second aerosol generating device 400) by the outer casing or tubular member 216 of the cartridge body 200.

In use, the mouthpiece or mouth end 220 of the cartridge body 200 of the aerosol delivery system 100 is inserted into the user's mouth. The atomizer/first aerosol generating device 212 is then activated, for example, by a user-performed puff (eg, suction) on the mouthpiece or on the mouth end 220 of the cartridge body 200. The heating element 240 and the liquid transfer element 238 are configured to be in a heat exchange relationship. Thus, the heat generated by the heating element 240 heats the composition to be aerosolized carried by the liquid transfer element 238 to generate a primary aerosol. The heat generated by the heating element 240 and the primary aerosol are then entrained in interaction with and through the second aerosol generating device 400 (i.e., through the aerosol generating element(s) 425) to the inhalation port formed by the mouthpiece or cooperating with a mouth end 220. In some cases, the heat from the heating element 240 may interact with the element(s) 425 to form an aerosol to generate a secondary aerosol. The secondary aerosol may interact with or mix with the primary aerosol to form a tertiary aerosol, the tertiary aerosol being the aerosol delivered to the user via the mouthpiece 220 in response to a pull applied thereto by the user. In some instances, the interaction between heat and/or the primary aerosol and the aerosol generating element(s) 425 may cause the enhancing agent to be incorporated into the primary aerosol to form the improved aerosol. For example, a medicament adsorbed onto the aerosol generating element(s) 425 may react with the primary aerosol and/or heat, or otherwise be deadsorbed from the aerosol generating element(s) 425 by the primary aerosol and/or heat, and combine with the primary aerosol and/or heat. aerosol to form an improved aerosol. In other cases, the aerosol generating element(s) 425 may be configured such that interaction with the primary aerosol causes heat to be drawn away from the primary aerosol (i.e., cooling of the primary aerosol occurs). When appropriately implemented by the user, at least the primary aerosol produced by the atomizer 212 and the aerosol that has been exposed to the second aerosol generating device 400 are produced and delivered to the user's mouth.

The components of the second aerosol generating device 400 and/or the aerosol generating element(s) 425 placed therein may be different. Typically, the second aerosol generating device 400 and/or the aerosol generating element(s) 425 accommodated therein may contain components that can be vaporized, aerosolized, or entrained in air drawn through the aerosol delivery system 100 during use. Most preferably, these components, alone or together with the primary aerosol produced by the first aerosol generating device 212, provide sensory and organoleptic effects such as smell, aroma, taste impression, sensations associated with visible aerosol, and the like. Examples of components of the first and/or second aerosol generating devices 212, 400 that are drawn into the wearer's mouth during puffing include water (e.g., in the form of water vapor), visible or non-visibly aerosolizing materials (e.g., glycerin), various volatile aromatics (eg vanillin and menthol), tobacco volatiles (eg nicotine), and the like.

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

The aerosol forming materials are carried or supported by substrate materials to support these aerosol materials within the desired area of the smoking article. Exemplary support materials and exemplary formulations containing aerosol forming materials are set forth in US Pat. No. 4,793,365 (Sensabaugh et al.); U.S. Patent No. 4,893,639 (White); U.S. Patent No. 5,099,861 (Clearman et al.); US Pat. No. 5,101,839 (Jakob et al.); US Pat. No. 5,105,836 (Gentry et al.); US Pat. No. 5,159,942 (Brinkley et al.); U.S. Patent No. 5,203,355 (Clearman et al.); U.S. Patent No. 5,271,419 (Arzonico et al.); US Pat. No. 5,327,917 (Lekwauwa et al.); US patent No. 5,396,911 (Casey, III and others); US Pat. No. 5,533,530 (Young et al.); U.S. Patent No. 5,588,446 (Clearman); US Pat. No. 5,598,868 (Jakob et al.); and US Pat. No. 5,715,844 (Young et al.); and US Published Application No. 2005/0066986 (Nestor et al.); the contents of which are incorporated into this application by reference. See also " Chemical and Biological Studies of New Cigarette Prototypes That Heat Rather Than Burn Tobacco ", a monograph by the RJ Reynolds Tobacco Company (1988). Exemplary backing materials have been included within certain types of cigarettes commercially sold under the brand names "Premier" and "Eclipse" by the RJ Reynolds Tobacco Company.

In some instances, the aerosol delivery system described with reference to FIG. 1 can be used in a similar manner as commercially available electronic cigarettes. As a result, when smoking, the preferred aerosol delivery system 100 of the types disclosed herein is capable of producing a visible base aerosol arising primarily from the vaporized components of the first and second aerosol generating devices 212, 400, the visible aerosol in many respects resembling the mainstream tobacco smoke of a traditional cigarette type, in which burns shredded tobacco.

In another example, substantially the entire cartridge body 200 may be formed from one or more carbonaceous materials (see, for example, FIG. 5), which may provide advantages over other cartridge body configurations disclosed herein in terms of biodegradability. and no wires. In this regard, the heating element may contain carbon foam, the reservoir may contain carbonized cloth, and graphite may be used to form an electrical connection to the battery and controller. Examples of a carbon-based cartridge body are provided in U.S. Published Application No. 2015/0059780 (Davis et al.) or 2013/0255702 (Griffith et al.), the contents of which are incorporated herein by reference in their entirety. In some cases, the inclusion of the second aerosol generating device disclosed herein may also be applicable to such a carbon-based cartridge body. For example, as shown in FIG. 6A and 6B, the portion 625 (see, for example, FIG. 6A) of the cartridge element 600 placed toward the mouthpiece of the cartridge body can be formed or otherwise modified (see, for example, FIG. 6B) to provide one or more element(s) 425 to form an aerosol of the types disclosed here. Alternatively, a pre-assembled cartridge can be implemented containing such aerosol generating element(s) 425, or the cartridge element 600 and/or the outer shell receiving the cartridge element 600 can be configured to provide first and second spacer elements having between them elements for the formation of an aerosol, as otherwise disclosed here.

Many modifications and other features of the present invention set forth herein are obvious to a person skilled in the art having the knowledge presented in the foregoing descriptions and accompanying drawings. For example, those skilled in the art will appreciate that embodiments not expressly expressed herein may be practiced without departing from the scope of the present invention, and the features described herein for various embodiments may be compatible with each other and/or with known currently or with future developed technologies, without departing from the scope of the claims presented herein. Thus, it is to be understood that the present invention is not to be limited to the specific embodiments disclosed and that equivalents, modifications, and other embodiments are intended to be included within the scope of the appended claims. Although certain terms are used here, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims (72)

1. An aerosol supply system, comprising: a part in the form of a control housing, containing the first elongated tubular element having opposite ends, and placed in it a power source; And a cartridge body portion comprising a second tubular member having opposing first and second ends, the first end being engaged with one of the opposite ends of the control body portion, the cartridge body part further comprises a first aerosol generation device placed inside the second tubular element and configured to be operatively interacted with the energy source after engagement between one of the opposite ends of the control body part and the first end of the cartridge body part, the second end of the cartridge body portion faces the mouth end of the aerosol delivery system; And a second aerosol generating device positioned between the first aerosol generating device and the mouth-engaging end of the aerosol delivery system, the second aerosol generating device being releasably engaged with the cartridge body portion or housed within the second tubular element of the cartridge body portion ; the first separating element is placed inside the second tubular element between the first aerosol generation device and the second aerosol generation device. 2. The aerosol delivery system of claim 1, wherein the second aerosol generating device further comprises at least one aerosol generating element. 3. The aerosol delivery system of claim 2, wherein at least one aerosol generating element is selected from the group consisting of granules, tablets, spherical particles, discrete small particles, carbon pieces, molded carbon pieces, spherical ceramic particles, marumerized tobacco leaf pieces, extruded or compressed cylindrical or spherical elements, shredded tobacco leaf, fillers, flavorings, visible aerosol forming materials, binders, ovoid elements, irregularly shaped elements, crushed pieces, flakes, tobacco containing elements, elements containing visible aerosol forming material, absorbent material articles, absorbent material articles, capsules, microcapsules, honeycomb monolith, single porous structure, and combinations thereof. 4. The aerosol supply system according to any one of paragraphs. 2, 3, in which the first separating element is positioned to support at least one aerosol generating element within the second aerosol generating device and separate from the first aerosol generating device. 5. The aerosol supply system according to any one of paragraphs. 2-4, wherein the first aerosol generating device comprises a heating element, and the first separating element is configured to separate at least one aerosol generating element within the second aerosol generating device from the heating element of the first aerosol generating device. 6. The aerosol supply system according to any one of paragraphs. 1-5, in which the first separating element is not thermally conductive. 7. The aerosol supply system according to any one of paragraphs. 1-6, in which the first separating element is made of a heat-resistant material. 8. The aerosol supply system according to any one of paragraphs. 1-5, in which the first separating element is thermally conductive. 9. The aerosol supply system according to any one of paragraphs. 1-8, in which the first separating element is made with the possibility of passing through it the air flow. 10. The aerosol supply system according to any one of paragraphs. 1-9, in which the first separating element is a breathable element. 11. The aerosol supply system according to any one of paragraphs. 1-10, in which the first separator element is a cell screen. 12. The aerosol delivery system of claim 1, further comprising a second separating element positioned between the second aerosol generating device and the mouth engaging end. 13. The aerosol delivery system of claim 12, wherein the second aerosol generating device further comprises at least one aerosol generating element, the second separating element being positioned to support at least one aerosol generating element within the second aerosol generating device. aerosol so that the aerosol generating element is not lost through the mouth end. 14. An aerosol delivery system according to claim 12 or 13, wherein the second separating element is not thermally conductive. 15. An aerosol delivery system according to claim 12 or 13, wherein the second separating element is thermally conductive. 16. The aerosol supply system according to any one of paragraphs. 12-15, in which the second separating element is configured to pass through the air flow. 17. The aerosol supply system according to any one of paragraphs. 12-16, in which the second separation element is an air-permeable element. 18. The aerosol supply system according to any one of paragraphs. 12-17, in which the second separator element is a cell screen. 19. The aerosol supply system according to any one of paragraphs. 1-18, wherein the first aerosol generating device comprises a liquid reservoir disposed within the second tubular member and configured to receive a substance to be aerosolized used by the first aerosol generating device to generate a primary aerosol. 20. An aerosol delivery system according to claim 19, wherein the substance to be aerosolized is a substance that does not contain fragrances or acids. 21. The aerosol delivery system of claim 19, wherein the substance to be aerosolized is one of the following: glycerin, propylene glycol, water, saline, nicotine, or combinations thereof. 22. The aerosol supply system according to any one of paragraphs. 1-21, wherein the first aerosol generating device comprises a heating element configured to supply heat to form the primary aerosol, and the second aerosol generating device comprises at least one aerosol generating element, wherein the at least one aerosol generating element positioned to interact with said heat and primary aerosol drawn through it towards the mouth end in response to suction applied to the mouth end. 23. The aerosol delivery system of claim 22, wherein at least one aerosol generating element of the second aerosol generating device is configured to interact with one of the following: heat from a heating element of the first aerosol generating device and primary aerosol generated by the first device for the formation of an aerosol, for the formation of a secondary aerosol. 24. The aerosol supply system according to any one of paragraphs. 1-23, wherein the primary aerosol generated by the first aerosol generating device is configured to interact with the secondary aerosol generated by the second aerosol generating device to form a tertiary aerosol drawn towards the mouth engaging end in response to suction applied thereto. . 25. The aerosol supply system according to any one of paragraphs. 1-24, wherein at least one aerosol generating member of the second aerosol generating device is configured to interact with the primary aerosol and introduce an enhancing agent into the primary aerosol generated by the first aerosol generating device to form an improved aerosol drawn towards the interacting with the end mouth in response to suction applied to it. 26. The aerosol supply system according to any one of paragraphs. 1-25, in which at least one element for generating an aerosol of the second device for generating aerosol is configured to interact with the primary aerosol and remove heat from the primary aerosol generated by the first device for generating aerosol, to form a cooled aerosol drawn in the direction of the interacting with end mouth in response to suction applied to it. 27. The aerosol supply system according to any one of paragraphs. 1-21, wherein the first aerosol generating device comprises a heating element configured to supply heat to form the primary aerosol, and the second aerosol generating device comprises at least one aerosol generating element, wherein the at least one aerosol generating element the second aerosol generating device is configured to interact with one or more of the following: heat from the heating element of the first aerosol generating device and the primary aerosol generated by the first aerosol generating device to form a secondary aerosol. 28. The aerosol supply system according to any one of paragraphs. 1-21, wherein the first aerosol generating device comprises a heating element configured to supply heat to form the primary aerosol, and the second aerosol generating device comprises at least one aerosol generating element, wherein the at least one aerosol generating element the second aerosol generating device is configured to interact with one of the following: heat from the heating element of the first aerosol generating device and the primary aerosol generated by the first aerosol generating device to form a secondary aerosol. 29. The aerosol delivery system of claim 27 or 28, wherein at least one aerosol generating element of the second aerosol generating device is configured to interact with the primary aerosol produced by the first aerosol generating device to form a secondary aerosol. 30. The aerosol supply system according to any one of paragraphs. 1-29, wherein the second aerosol generating device comprises a plurality of aerosol generating elements in the form of spherical particles or tablets containing at least one aerosol forming material. 31. The aerosol delivery system of claim 30, wherein the aerosol generating elements comprise one or more of particulate tobacco, tobacco liquor and nicotine, wherein the nicotine is in free base form, in salt form, as a complex compound, or solvate. 32. The aerosol delivery system of claim 31, wherein the aerosol forming elements comprise one or more fillers, binders, flavors, and combinations thereof. 33. The aerosol supply system according to claim 32, wherein the elements for generating the aerosol are treated with smoke. 34. A method for forming an aerosol supply system, including: engagement of one end of the first elongated tubular element with the first end of the second tubular element, wherein the first elongated tubular element is made as a part in the form of a control housing and contains an energy source placed in it, and the second tubular element is made as a part in the form of a cartridge body and contains the first device for generating an aerosol placed therein, and the first device for generating an aerosol is made with the possibility of functional interaction with an energy source after engagement between the specified one end of the part in the form of a control body and the first end of the part in the form of a cartridge body, and the second end of the cartridge body portion faces the mouth-engaging end of the aerosol delivery system; And engaging a second aerosol generating device with the cartridge body portion such that the second aerosol generating device is interposed between the first aerosol generating device and a mouth-engaging end of the aerosol delivery system; And inserting the first separating element into the second tubular element between the first aerosol generating device and the second aerosol generating device. 35. The method of claim 34, wherein the step of engaging the second aerosol generating device with the cartridge body portion includes inserting the second aerosol generating device within a second tubular member of the cartridge body portion between the first aerosol generating device and the second end of the second tubular element, and the second end is opposite the first end and is formed as a mouth-engaging end. 36. The method of claim 34, wherein inserting the second aerosol generating device within the second tubular element further comprises inserting at least one aerosol generating element, at least partially forming the second aerosol generating device, into the second tubular element, wherein at least one element for forming an aerosol is selected from the group containing granules, tablets, particles of spherical shape, discrete small particles, carbon pieces, pieces of molded carbon, ceramic particles of spherical shape, marumerized pieces of tobacco leaf, extruded or compressed cylindrical or spherical elements, shredded tobacco leaf, fillers, flavorings, visibly aerosol forming materials, binding materials, egg-shaped elements, irregularly shaped elements, crushed pieces, flakes, tobacco-containing elements, elements containing aerosolically forming material, absorbent material objects, absorbent material objects, capsules , microcapsules, honeycomb monolith, single porous structure and their combinations. 37. The method of claim 36, wherein the first separation member is positioned to support at least one aerosol generating member within the second aerosol generating device and separate from the first aerosol generating device. 38. The method of claim 36 or 37, wherein the first aerosol generating device comprises a heating element and the first separating element is configured to separate at least one aerosol generating element within the second aerosol generating device from the heating element of the first aerosol generating device. aerosol. 39. The method according to any one of paragraphs. 34-38, in which the first separating element is not thermally conductive. 40. The method according to any one of paragraphs. 34-39, in which the first separating element is made of a heat-resistant material. 41. The method according to any one of paragraphs. 34-38, in which the first separating element is thermally conductive. 42. The method according to any one of paragraphs. 34-41, in which the first separating element is configured to pass through the air flow. 43. The method according to any one of paragraphs. 34-42, in which the first separating element is a breathable element. 44. The method according to any one of paragraphs. 34-43, in which the first separator element is a cell screen. 45. The method of claim 34, further comprising inserting the second spacer into the second tubular member between the second aerosol generating device and the mouth engaging end of the cartridge body portion. 46. The method of claim 45, wherein the second aerosol generating device further comprises at least one aerosol generating element, wherein the second separating element is positioned to support at least one aerosol generating element within the second aerosol generating device so that the aerosol generating element is not lost through the mouth end. 47. The method according to claim 45 or 46, in which the second separating element is not thermally conductive. 48. The method according to claim 45 or 46, wherein the second separating element is thermally conductive. 49. The method according to any one of paragraphs. 45-48, in which the second separating element is configured to pass through the air flow. 50. The method according to any one of paragraphs. 45-49, in which the second separating element is a breathable element. 51. The method according to any one of paragraphs. 45-50, in which the second separator element is a cell screen. 52. The method of claim 46 wherein the second aerosol generating device comprises a plurality of aerosol generating elements in the form of spherical particles or tablets held in place by a first air-permeable spacer positioned within the second tubular member between the first aerosol generating device and the second an aerosol generating device; and a second separating element between the second aerosol generating device and the mouth engaging end. 53. The method according to any one of paragraphs. 34-52, wherein engaging the second aerosol generating device with the cartridge body portion includes releasably engaging the second aerosol generating device with the cartridge body portion, the second aerosol generating device comprising a first end capable of being engaged with detachable from the cartridge body part, and a second end configured to provide a mouth-engaging end of the aerosol delivery system, the second aerosol generating device comprising a plurality of elements for generating aerosol in the form of spherical particles or tablets held in place by the first air-permeable a separating element between the first aerosol generating device and the second aerosol generating device and a second separating element between the second aerosol generating device and the mouth engaging end. 54. The method according to any one of paragraphs. 34-53, wherein the second aerosol generating device comprises a plurality of aerosol forming elements in the form of spherical particles or tablets containing at least one aerosol forming material. 55. The method of claim 54, wherein the aerosol generating elements further comprise one or more of particulate tobacco, tobacco infusion, and nicotine, wherein the nicotine is in free base, salt, complex, or solvate form. . 56. The method of claim 55, wherein the aerosol generating elements further comprise one or more fillers, binders, flavors, and combinations thereof. 57. The method of claim 55, wherein the aerosol generating elements are treated with smoke. 58. The method according to any one of paragraphs. 34-57, wherein the first aerosol generating device comprises a heating element configured to supply heat to form the primary aerosol, and the second aerosol generating device comprises at least one aerosol generating element, wherein the at least one aerosol generating element of the second aerosol generating device interacts with one of the following: heat from the heating element of the first aerosol generating device and the primary aerosol generated by the first aerosol generating device to form a secondary aerosol. 59. The method according to any one of paragraphs. 34-57, wherein the first aerosol generating device comprises a heating element configured to supply heat to form the primary aerosol, and the second aerosol generating device comprises at least one aerosol generating element, wherein the at least one aerosol generating element the second aerosol generating device interacts with one or more of the following: heat from the heating element of the first aerosol generating device and the primary aerosol generated by the first aerosol generating device to form a secondary aerosol. 60. The method of claim 58 or 59, wherein at least one aerosol generating member of the second aerosol generating device is configured to interact with primary aerosol generated by the first aerosol generating device to form a secondary aerosol.

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