RU2826035C2 - Smoking product, method for its manufacture and aerosol producing cartridge - Google Patents

Abstract

FIELD: smoking devices.

SUBSTANCE: group of inventions relates to a smoking article, a method for its manufacture, and an aerosol-producing cartridge. The smoking article comprises a part of the mouth end, a control housing containing at least a part of the heating device, wherein at least part of the heating device comprises a resonant transmitter of the induction heater, and an aerosol-producing cartridge that is in fluid communication with a part of the mouth end and interacts with the control housing. The cartridge comprises a shell configured to accommodate an aerosol precursor configured to produce an aerosol when heated, wherein at least a portion of the shell is permeable such that the aerosol precursor is retained within the shell while allowing the release of an aerosol formed from aerosol precursor, from the shell through the permeable part and transfer to the mouth end part when the shell or aerosol precursor in it is heated. The smoking article comprises a resonant receiver configured to interact with the resonant transmitter to generate heat to heat the sheath or aerosol precursor therein.

EFFECT: delivery of aerosol without products of incomplete combustion and pyrolysis.

39 cl, 5 dwg

Description

AREA OF TECHNOLOGY

The present invention relates to products that contain tobacco and are intended for human consumption and, more particularly, to smoking articles that form inhalable aerosols that have significantly lower amounts of incomplete combustion and pyrolysis products compared to tobacco products that emit smoke when tobacco is burned.

LEVEL OF TECHNOLOGY

Popular smoking articles such as cigarettes have a substantially cylindrical rod-shaped structure and include a mass, roll or column of smokable material such as shredded tobacco (e.g. in the form of cut filler), surrounded by a paper wrapper, thereby forming what is known as a "smoking rod", "tobacco rod" or "cigarette rod". Typically, a cigarette has a cylindrical filter element aligned in an end-to-end arrangement with the tobacco rod. Preferably, the filter element comprises a plasticized rope of cellulose acetate surrounded by a paper material known as a "plug wrap". Preferably, the filter element is attached to one end of the tobacco rod using a restrictive wrapping material known as a "tipping paper". To ensure that the drawn mainstream smoke is diluted with ambient air, it has also become desirable to perforate the rim material and the ficella. Cigarettes and their various components are described in Tobacco Production, Chemistry and Technology, Davis et al. (eds.) (1999). The user uses a traditional-style cigarette by lighting one end of the cigarette and burning the tobacco rod. The user then draws the mainstream smoke into the mouth by drawing on the opposite end (e.g., the filter end or mouth end) of the cigarette. Over the years, efforts have been made to improve the components, design, and performance of smoking articles. See, for example, the "Prior Art" described in U.S. Patent No. 7,753,056 to Borschke et al.

As an alternative to burning tobacco, certain types of cigarettes that use carbonaceous fuel cells are available commercially under the trade names Premier, Eclipse, and Revo, manufactured by R. J. Reynolds Tobacco Company. See, for example, the types of cigarettes described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco by R. J. Reynolds Tobacco Company (1988) and Inhalation Toxicology, 12:5, p. 1 58 (2000). Additionally, a similar type of cigarette was available commercially in Japan, manufactured by Japan Tobacco Inc. under the trade name Steam Hot One.

In addition, various types of smoking products incorporating carbonaceous fuel elements for generating heat and aerosol have recently been disclosed in the patent literature. See, for example, the types of smoking products disclosed in U.S. Patents 7,836,897 to Borschke et al.; 8,469,035 to Banerjee et al.; and 8,464,726 to Sebastian et al.; 8,616,217 to Tsuruizumi et al.; 8,915,255 to Poget et al.; 9,578,897 to Gladden et al.; 9,185,939 to Zuber et al.; No. 7,692,123 to Baba et al.; No. 8,616,217 to Tsuruizumi et al.; U.S. Patent Publication No. 2012/0042885 to Stone et al.; No. 2013/0133675 to Shinozaki et al. and PCT WO No. 2013/098380 to Raether et al.; No. 2013/098405 to Zuber et al.; No. 2013/098410 to Zuber et al.; No. 2013/104914 to Woodcock; No. 2013/120849 to Roudier et al.; No. 2013/120854 to Mironov, which are incorporated herein by reference in their entirety. A historical perspective on technology relating to various types of smoking products incorporating carbonaceous fuel elements for heat and aerosol generation can be found, for example, in the Background of U.S. Patent Publication No. 2007/0215167 to Llewellyn Crooks et al., which is also incorporated herein by reference.

Over the years, many other smoking articles have been proposed as improvements or alternatives to smoking products based on the combustion of tobacco. Typical alternatives include devices in which a solid or liquid fuel is burned to transfer heat to the tobacco or in which a chemical reaction is used to provide such a heat source. Examples include the smoking articles described in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference.

The aim of improvements or alternatives to smoking products has generally been to provide the sensations associated with smoking cigarettes, cigars or pipes, but without delivering significant amounts of incomplete combustion and pyrolysis products. To this end, many smoking products, aroma generators and medicinal inhalers have also been proposed that use electrical energy to vaporize or heat a volatile material or attempt to provide the sensations of smoking cigarettes, cigars or pipes without significantly burning the tobacco.

It is particularly advantageous to provide smoking articles that exhibit the ability to provide the user with a significant portion of the pleasure of conventional cigarette smoking without delivering an aerosol that includes significant amounts of incomplete combustion and pyrolysis products.

DISCLOSURE OF THE ESSENCE OF THE INVENTION

In various embodiments, the present invention provides a smoking article comprising a portion of the mouth end and an aerosol-generating cartridge in fluid communication with the portion of the mouth end. The smoking article also includes a shell configured to accommodate an aerosol precursor therein. The aerosol precursor is configured to generate an aerosol upon heating. At least a portion of the shell is permeable such that the aerosol precursor is retained within the shell, while the aerosol formed from the aerosol precursor is capable of being released from the shell through the permeable portion upon heating of the shell or the aerosol precursor therein.

In various embodiments, the present invention provides an aerosol-generating cartridge for use in a smoking article. The cartridge comprises an aerosol precursor and a shell configured to accommodate the aerosol precursor. The aerosol precursor is configured to generate an aerosol upon heating. At least a portion of the shell is permeable such that the aerosol precursor is retained within the shell, while the aerosol formed from the aerosol precursor is capable of being released from the shell through the permeable portion upon heating of the shell or the aerosol precursor in it.

In various embodiments, the present invention provides a method for producing a smoking article. The method includes inserting an aerosol precursor into a shell. The aerosol precursor is designed to generate an aerosol upon heating. At least a portion of the shell is permeable such that the aerosol precursor is retained within the shell, while the aerosol formed from the aerosol precursor is capable of being released from the shell through the permeable portion upon heating of the shell or the aerosol precursor therein. The method also includes at least partial confinement of the aerosol-generating cartridge by a first wrapping material to form a subassembly of the smoking article.

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

Embodiment 1: A smoking article comprising: a portion of a mouthpiece end and an aerosol-generating cartridge in fluid communication with the portion of the mouthpiece end and comprising: a shell configured to accommodate an aerosol precursor configured to generate an aerosol upon heating, wherein at least a portion of the shell is permeable such that the aerosol precursor is retained within the shell while the aerosol formed from the aerosol precursor is capable of being released from the shell through the permeable portion upon heating of the shell or the aerosol precursor therein.

Implementation option 2: A smoking article according to any preceding implementation option or any combination of the preceding ones

embodiments, also comprising a flammable heat-generating element located opposite the aerosol-generating cartridge from the mouthpiece end portion of the smoking article, wherein the heat-generating element consists of a carbonized material or a pyrolyzed material.

Implementation option 3: A smoking article according to any preceding implementation option or any combination of the preceding ones

embodiments, also comprising a tobacco rod located between the aerosol-producing cartridge and a portion of the mouthpiece end or between the aerosol-producing cartridge and the heat-generating element.

Implementation option 4: A smoking article according to any preceding implementation option or any combination of the preceding ones

embodiments in which a portion of the mouthpiece end comprises a filter element in fluid communication with the aerosol-generating cartridge.

Implementation option 5: A smoking article according to any preceding implementation option or any combination of the preceding ones

embodiments, in which the aerosol precursor comprises tobacco beads, tobacco pellets, extruded tobacco, cast sheet tobacco in the form of cut filler, a sheet of reconstituted tobacco material in the form of cut filler, aerosol-forming beads, aluminum oxide beads, a ceramic material, a cast sheet of non-tobacco material in the form of cut filler, a glass mat, a foil sheet, collected paper or gel, or various combinations thereof.

Embodiment 6: A smoking article according to any preceding embodiment or any combination of the preceding embodiments

embodiments in which the shell consists of tobacco, paper or metal or various combinations thereof.

Implementation option 7: A smoking article according to any preceding implementation option or any combination of the preceding ones

embodiments in which the shell consists of a multilayer material of paper and foil.

Embodiment 8: A smoking article according to any preceding embodiment or any combination of the preceding embodiments

embodiments in which the shell includes an elongated peripheral wall forming an elongated hollow cylinder having opposite first and second longitudinal ends, and first and second end walls extending respectively laterally across the first and second longitudinal ends of the peripheral wall.

Embodiment 9: A smoking article according to any preceding embodiment or any combination of the preceding embodiments

embodiments in which one of the first end wall and the second end wall is perforated to release the aerosol from the shell.

Embodiment 10: A smoking article according to any preceding embodiment or any combination of the preceding embodiments

embodiments in which the first end wall and the second end wall are perforated.

Embodiment 11: A smoking article according to any preceding embodiment or any combination of the preceding embodiments

embodiments in which one of the first end wall and the second end wall is offset from the corresponding first and second longitudinal end of the peripheral wall.

Embodiment 12: A smoking article according to any preceding embodiment or any combination of the preceding embodiments

embodiments in which the first end wall includes a first part and a second part, wherein the first part and the second part are not coplanar.

Embodiment 13: A smoking article according to any preceding embodiment or any combination of the preceding embodiments

embodiments in which the first part is offset from the second part along the longitudinal axis of the peripheral wall.

Embodiment 14: A smoking article according to any preceding embodiment or any combination of the preceding embodiments

embodiments in which the shell is symmetrical relative to the longitudinal axis of the peripheral wall.

Embodiment 15: A smoking article according to any preceding embodiment or any combination of the preceding embodiments

embodiments in which the shell is symmetrical relative to a plane dividing the peripheral wall in half between its first and second ends.

Embodiment 16: A smoking article according to any preceding embodiment or any combination of the preceding embodiments

embodiments in which one of the first wall and the second end wall is formed separately from the peripheral wall and is bonded to the peripheral wall by welding, adhesive, or friction fit.

Embodiment 17: A smoking article according to any preceding embodiment or any combination of the preceding embodiments

embodiments in which one of the first wall and the second wall includes a folded wrapping material extending laterally across one of the first or second longitudinal ends of the peripheral wall and along the peripheral wall as a layer thereof.

Embodiment 18: A smoking article according to any preceding embodiment or any combination of the preceding embodiments

embodiments, also comprising a control body comprising at least a portion of a heating device associated with a receiving socket formed by the control body, wherein the receiving socket is configured to receive an end portion of the smoking article, wherein the end portion is opposite to the mouthpiece end portion and has an aerosol-generating cartridge associated therewith.

Embodiment 19: A smoking article according to any preceding embodiment or any combination of the preceding embodiments

embodiments in which the heating device is a resistive electric heater configured to generate heat for heating the shell or aerosol precursor therein.

Embodiment 20: A smoking article according to any preceding embodiment or any combination of the preceding embodiments

embodiments in which the heating device is an induction heater containing a resonant transmitter.

Embodiment 21: A smoking article according to any preceding embodiment or any combination of the preceding embodiments

embodiments in which the aerosol-generating cartridge comprises a resonant receiver configured to interact with the resonant transmitter to generate heat for heating the shell or an aerosol precursor therein.

Embodiment 22: A smoking article according to any preceding embodiment or any combination of preceding embodiments, wherein the resonant receiver is attached to the aerosol-generating cartridge.

Embodiment 23: A smoking article according to any preceding embodiment or any combination of preceding embodiments, the shell includes a resonant receiver.

Embodiment 24: A smoking article according to any preceding embodiment or any combination of preceding embodiments, wherein the aerosol-generating cartridge comprises a plurality of aerosol-generating cartridges, wherein the aerosol precursor in a first one of the plurality of aerosol-generating cartridges has at least one different component from the aerosol precursor in a second one of the plurality of aerosol-generating cartridges.

Embodiment 25: A smoking article according to any preceding embodiment or any combination of preceding embodiments, wherein the first one of the plurality of aerosol-producing cartridges and the second one of the plurality of aerosol-producing cartridges are sequentially arranged relative to each other.

Embodiment 26: A smoking article according to any preceding embodiment or any combination of preceding embodiments, further comprising a wrapper material that defines at least a portion of the aerosol-generating cartridge, wherein the wrapper material comprises a laminate of paper and foil sheets, a laminate of paper, foil and paper sheets, a laminate of paper, foil and tobacco sheets, a non-woven graphite sheet, a graphene sheet, a laminate of graphene and foil sheets, a laminate of graphene, foil and paper sheets, a laminate of paper and graphene sheets, graphene ink printed on a paper sheet, graphene ink printed on a foil sheet, carbon nanotubes interacting with a paper sheet or a foil sheet, fullerenes interacting with a paper sheet or a foil sheet, or graphene interacting with a paper sheet or foil sheet, or various combinations of these.

Embodiment 27: An aerosol-generating cartridge for use in a smoking article, comprising: an aerosol precursor and a shell configured to accommodate the aerosol precursor, wherein the aerosol precursor is configured to generate an aerosol upon heating, wherein at least a portion of the shell is permeable such that the aerosol precursor is retained within the shell, while the aerosol formed from the aerosol precursor is capable of being released from the shell through the permeable portion upon heating of the shell or the aerosol precursor therein.

Embodiment 28: A cartridge according to any preceding embodiment or any combination of preceding embodiments, wherein the aerosol precursor comprises tobacco beads, tobacco pellets, extruded tobacco, cast sheet tobacco in the form of cut filler, a sheet of reconstituted tobacco material in the form of cut filler, aerosol-forming beads, aluminum oxide beads, a ceramic material, a cast sheet of non-tobacco material in the form of cut filler, a glass mat, a foil sheet, collected paper or gel, or various combinations thereof.

Embodiment 29: A cartridge according to any preceding embodiment or any combination of the preceding embodiments

embodiments in which the shell consists of tobacco, paper or metal or various combinations thereof.

Embodiment 30: A cartridge according to any preceding embodiment or any combination of preceding embodiments, wherein the shell consists of a multilayer material of paper and foil.

Embodiment 31: A cartridge according to any preceding embodiment or any combination of preceding embodiments, wherein the shell includes an elongated peripheral wall defining an elongated hollow cylinder having opposite first and second longitudinal ends, and first and second end walls extending laterally across the first and second longitudinal ends of the peripheral wall, respectively.

Embodiment 32: A cartridge according to any preceding embodiment or any combination of preceding embodiments, wherein one of the first end wall and the second end wall is perforated to release the aerosol from the shell.

Embodiment 33: A cartridge according to any preceding embodiment or any combination of preceding embodiments, wherein the first end wall and the second end wall are perforated.

Embodiment 34: A cartridge according to any preceding embodiment or any combination of preceding embodiments, wherein one of the first end wall and the second end wall is offset from the corresponding first and second longitudinal end of the peripheral wall.

Embodiment 35: A cartridge according to any preceding embodiment or any combination of preceding embodiments, wherein the first end wall includes a first portion and a second portion, wherein the first portion and the second portion are not coplanar.

Embodiment 36: A cartridge according to any preceding embodiment or any combination of the preceding embodiments.

embodiments in which the first part is offset from the second part along the longitudinal axis of the peripheral wall.

Embodiment 37: A cartridge according to any preceding embodiment or any combination of the preceding embodiments.

embodiments in which one of the first wall and the second end wall is formed separately from the peripheral wall and is bonded to the peripheral wall by welding, adhesive, or friction fit.

Embodiment 38: A cartridge according to any preceding embodiment or any combination of the preceding embodiments.

embodiments in which one of the first wall and the second wall includes a folded wrapping material extending laterally across one of the first or second longitudinal ends of the peripheral wall and along the peripheral wall as a layer thereof.

Embodiment 39: A cartridge according to any preceding embodiment or any combination of the preceding embodiments.

embodiments in which the shell is symmetrical relative to the longitudinal axis of the peripheral wall.

Embodiment 40: A cartridge according to any preceding embodiment or any combination of the preceding embodiments.

embodiments in which the shell is symmetrical relative to a plane dividing the peripheral wall in half between its first and second ends.

Embodiment 41: A method for manufacturing a smoking article, comprising: inserting an aerosol precursor into a shell, wherein the aerosol precursor is configured to generate an aerosol upon heating, wherein at least a portion of the shell is permeable such that the aerosol precursor is retained within the shell, while the aerosol formed from the aerosol precursor is capable of being released from the shell through the permeable portion upon heating of the shell or the aerosol precursor therein, and at least partially restricting the aerosol-generating cartridge with a first wrapping material to form a subassembly of the smoking article.

Embodiment 42: The method of any preceding embodiment or any combination of the preceding embodiments

embodiments, according to which inserting the aerosol precursor includes inserting the aerosol precursor into a chamber formed by a peripheral wall of the shell, wherein the method includes at least partially closing one end of the peripheral wall with an end wall to retain the aerosol precursor within the chamber.

Embodiment 43: The method of any preceding embodiment or any combination of the preceding embodiments

embodiments, according to which closing one end of the chamber with an end wall includes wrapping a wrapping layer around a peripheral wall, wherein the wrapping layer has an end region extending beyond the longitudinal end of the peripheral wall, and folding the end region of the wrapping layer in the transverse direction along the longitudinal end of the peripheral wall to form an end wall.

Embodiment 44: The method of any preceding embodiment or any combination of the preceding embodiments

embodiments, according to which at least partially restricting the aerosol-generating cartridge includes at least partially restricting the aerosol-generating cartridge and the heat-generating element with a first wrapper material to form a subassembly of the smoking article.

Embodiment 45: The method of any preceding embodiment or any combination of the preceding embodiments

embodiments according to which the heat-generating element comprises a flammable heating element or an induction receiver of an induction heater.

Embodiment 46: The method of any preceding embodiment or any combination of the preceding embodiments

embodiments, according to which at least partially restricting the aerosol-producing cartridge includes at least partially restricting the aerosol-producing cartridge and the tobacco rod, sequentially located relative to it, with a first wrapping material to form a sub-assembly of the smoking article.

Embodiment 47: The method according to any preceding embodiment or any combination of the preceding

embodiments, also including the sequential arrangement of the filter element with the sub-assembly of the smoking article and the limitation of at least a part of the sub-assembly of the smoking article and the filter element with a second wrapping material to form the smoking article.

Embodiment 48: The method of any preceding embodiment or any combination of the preceding embodiments

embodiments, according to which the sequential arrangement of the filter element also includes a sequential arrangement of the filter element with a sub-assembly of the smoking article containing an aerosol-producing cartridge located between the heat-producing element and the tobacco rod and limited by the first wrapping material.

These and other features, aspects and advantages of the present invention will become apparent from a reading of the following detailed description with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four or more features or elements set forth in the present disclosure or recited in any one or more claims, regardless of whether such features or elements are explicitly combined or otherwise recited in the detailed description of an embodiment or the appended claims. The present invention is intended to be read as a whole, so that any individual features or elements of the invention in any of its aspects and embodiments should be considered as combinable unless the context of the invention clearly dictates otherwise.

It should be understood, therefore, that this disclosure is provided only for the purpose of summarizing some exemplary embodiments so as to provide a basic understanding of some aspects of the invention. It should be understood, therefore, that the embodiments described above are merely examples and should not be construed as in any way narrowing the scope or spirit of the invention. Other exemplary embodiments, aspects and advantages should become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of some of the described exemplary embodiments.

BRIEF DESCRIPTION OF DRAWINGS

Having therefore described the present invention in the general terms set forth above, reference is now made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

FIG. 1 is a schematic longitudinal sectional view of a representative smoking article according to one aspect of the invention;

FIG. 2 is a schematic perspective view of an aerosol generating cartridge for use in the smoking article of FIG. 1.

FIG. 3 is a schematic cross-sectional view of the aerosol-generating cartridge of FIG. 2.

FIG. 4 is a schematic cross-sectional view of a second representative smoking article according to one aspect of the invention.

FIG. 5 is a schematic illustration of an aerosol generating cartridge according to one aspect of the invention, included in an aerosol source element subject to electrical heating.

IMPLEMENTATION OF THE INVENTION

The present invention will now be described more fully with reference to exemplary embodiments thereof. These exemplary embodiments are described so that the present description is thorough and complete and fully conveys the scope of the present invention to those skilled in the art. Indeed, the present invention may be embodied in many different forms and should not be considered as limited to the embodiments shown herein; rather, the said embodiments are provided so that the present invention complies with applicable legal requirements. In this description and in the appended claims, a grammatical construction indicating that an element is given in the singular also includes the plural unless the context of the invention clearly dictates otherwise. Furthermore, although reference may be made herein to quantities, values, geometric relationships or the like, unless otherwise indicated, any one or more, if not all, of them may be absolute or approximate in order to account for reasonable variations that may occur, for example, due to engineering tolerances or the like.

FIG. 1 shows a representative smoking article 10 in the form of a cigarette according to one aspect of the present invention. The smoking article 10 may have the general size, shape and general appearance of a filter cigarette. In the embodiment shown, the smoking article 10 has a rod-shaped form and includes a heated portion 14 and a mouth end portion 18. On the heated portion 14 (which in some aspects, but not necessarily, is at the end of the smoking article 10) is located a longitudinally extending, generally cylindrical, heat-generating portion 35. The heat-generating portion 35 includes a heat source 40, defined by insulation 42, which is most preferably coaxially surrounded by an outer wrapping material 45. In the embodiment shown, the heat source 40 is preferably configured to be activated by direct ignition of the heated portion 14. In other words, the heat source or fuel element is intended to be ignited in order to burn or smoulder and, therefore, to generate heat. The smoking article 10 may also include a filter portion 55 located at the opposite end (for example, the mouth end portion 18) relative to the heated portion 14. Between the filter portion 55 and the heat generating portion 35, an aerosol generating portion 65 is located, which may include at least one aerosol generating cartridge 68 and may optionally include a tobacco rod 70. In various embodiments, other components may be present between the aerosol generating cartridge 68 and the mouth end portion 18. For example, in some embodiments, one or any combination of the following may be used: an air gap; phase change materials for cooling the air; a means for releasing the aroma; ion exchange fibers capable of selective chemical adsorption; aerogel particles as a filter medium and other suitable materials.

The heat generating portion 35 most preferably includes a combustible heat source 40 that has a generally cylindrical shape and includes a combustible carbonaceous material. Examples of combustible fuel elements are described in U.S. Patent No. 2017/0000188 to Nordskog, which is incorporated herein by reference in its entirety. Such combustible carbonaceous materials typically have a high carbon content. Preferred carbonaceous materials are composed predominantly of carbon, typically having a carbon content greater than about 60 percent, typically greater than about 70 percent, often greater than about 80 percent, and most often greater than about 90 percent on a dry weight basis. Such combustible fuel elements may include components other than combustible carbonaceous materials (e.g., tobacco components such as powdered tobaccos or tobacco extracts; flavorings; salts such as sodium chloride, potassium chloride and sodium carbonate; heat-resistant graphite fibers; iron oxide powder; glass threads; powdered calcium carbonate; aluminum oxide granules; ammonia sources such as ammonia salts and/or binding agents such as guar gum, ammonium alginate and sodium alginate). A representative heat source 40, for example, has a length of about 12 mm and an overall outer diameter of about 4.2 mm. The representative heat source 40 may be extruded or mixed using ground or powdered carbonaceous material and has a density that is greater than about 0.5 g/ ^cm3 , often greater than about 0.7 g/ ^cm3 , and most often greater than about 1 g/ ^cm3 , on a dry weight basis.

Another embodiment of the heat source 40 may include a foamed carbon monolith formed by a foaming process. In another embodiment, the heat source 40 may be co-extruded with the insulation 42, thereby reducing manufacturing time and costs. Still other embodiments of heat sources, also referred to as fuel cells, may include those of the types described in U.S. Patent No. 4,819,655 to Roberts et al. or in U.S. Patent Application Publication No. 2009/0044818 to Takeuchi et al., each of which is incorporated herein by reference.

The carbonaceous fuel elements providing the heat source 40 may also include the types of components and configurations that have been incorporated into these cigarettes sold under the trademarks "Premier," "Eclipse," "Revo," and "Steam Hot One." Additionally, representative types of heat-generating portions, fuel element features, and representative components, structures and configurations thereof, and methods and techniques for making these heat-generating portions and fuel elements thereof are set forth in U.S. Patents 4,714,082 to Banerjee et al.; 4,756,318 to Clearman et al.; 4,881,556 to Clearman et al.; 4,989,619 to Clearman et al.; 5,020,548 to Farrier et al.; #5,027,837 by Clearman et al.; #5,067,499 by Banerjee et al.; #5,076,297 by Farrier et al.; #5,099,861 by Clearman et al.; #5,105,831 by Banerjee et al.; #5,129,409 by White et al.; #5,148,821 by Best et al.; #5,156,170 by Clearman et al.; #5,178,167 by Riggs et al.; #5,211,684 by Shannon et al.; #5,247,947 by Clearman et al.; #5,345,955 by Clearman et al.; #5,461,879 by Barnes et al.; #5,469,871 by Barnes et al.; #5,551,451 by Riggs; #5,560,376 by Meiring et al.; #5,706,834 by Meiring et al.; #5,727,571 by Meiring et al.; #7,836,897 by Borschke et al.; No. 8,617,263 by Banerjee et al. and No. 8,678,013 by Crooks; No. 9,220,301 by Banerjee; No. 9,345,268 by Stone et al.; No. 9,788,571 to Conner et al. and U.S. Patent Application Publication No. 2005/0274390 to Banerjee et al. and U.S. Patent Application Publication No. 2012/0042885 to Stone et al. See also the types of fuel cell configurations and components thereof described in U.S. Patent No. 4,819,655 to Roberts et al. and U.S. Patent Application Publication No. 2009/0044818 to Takeuchi et al.

Some fuel elements may contain a high carbon content carbonaceous material that is derived from cotton fiber (e.g., cotton linters) that has been carbonized or pyrolyzed. For a description of cotton linters that have been carbonized or pyrolyzed and the methods and processes by which these materials have been incorporated into smoking articles, carbonized smoking articles, and fuel elements, see, e.g., U.S. Patents 4,219,031 to Rainer et al.; 4,920,990 to Lawrence et al.; 5,007,440 to Robinson et al.; 5,060,673 to Lehman; 5,129,409 to White et al.; 5,211,684 to Shannon et al.; and No. 8,119,555 by Banerjee et al.

The insulation 42 of the heat-generating portion 35 may be comprised of glass threads or fibers. The insulation 42 may act as a jacket that helps to tightly hold the heat source 40 in place within the smoking article 10 (e.g., located between the heat source and the wrapping material 45). In an embodiment, the insulation 42 is provided in the form of a non-woven substrate made of glass fibers. The insulation 42 may be provided in the form of a multi-layer component, for example, comprising an inner layer or substrate 75 of non-woven glass threads, an intermediate layer of reconstituted paper 76 for tobacco packaging and an outer layer of non-woven glass threads 77. These layers may be oriented concentrically, or each of them may be wrapped around the heat source 40 and/or limit it with a continuous overlap. Various other embodiments of the insulation may be molded, extruded, foamed or otherwise formed. Specific embodiments of the insulating structures may include those described in U.S. Patent Application Publication No. 2012/0042885 to Stone et al., which is incorporated herein by reference in its entirety.

Additionally, the insulation may be designed to permit the drawn air and aerosol to pass readily therethrough. Suitable insulation assemblies have been incorporated into these types of cigarettes sold under the trademarks "Premier," "Eclipse," and "Steam Hot One." Examples of insulation materials, components of the insulation assemblies, configurations of representative insulation assemblies in heat-producing portions, wrapping materials for the insulation assemblies, and methods and techniques for making these components and assemblies are further set forth in U.S. Patents 4,807,809 to Pryor et al.; 4,893,637 to Hancock et al.; 4,938,238 to Barnes et al.; 5,027,836 to Shannon et al.; #5,065,776 by Lawson, et al.; #5,105,838 by White, et al.; #5,119,837 by Banerjee, et al.; #5,247,947 by Clearman, et al.; #5,303,720 by Banerjee, et al.; #5,345,955 by Clearman, et al.; #5,396,911 by Casey, III, et al.; #5,546,965 by White; #5,727,571 by Meiring, et al.; #5,902,431 by Wilkinson, et al.; #5,944,025 by Cook et al.; #8,424,538 by Thomas et al.; #8,464,726 by Sebastian et al.; and #8,678,013 by Crooks et al.

In one embodiment, both ends of the heat-generating portion 35 are open to expose at least the heat source 40 and the insulation 42 on the heated portion 14. The heat source 40 and the surrounding insulation 42 can be designed such that the length of both materials is the same (for example, the ends of the insulation 42 are flush with the corresponding ends of the heat source 40 and, in particular, at the downstream end of the heat-generating portion 35). If necessary, the insulation 42 can extend slightly beyond (for example, from about 0.5 mm to about 2 mm further) one or both ends of the heat source 40. Moreover, the heat and/or the generated heated air during ignition of the heated portion 14 during use of the smoking article 10 can easily pass through the heat generating portion 35 during the user's puff on the mouthpiece end portion 18, through the heat source 40 itself (for example, through a longitudinal channel passing through the heat source 40) and/or in the longitudinal direction through the insulation 42.

In one embodiment, the wrapping material 45 defines the insulation 42 along the longitudinally extending outermost surface of the heated portion 14 of the smoking article 10. The wrapping material 45 may be a paper wrapping material, such as, for example, the type of paper wrapping materials used as defining wrapping materials for areas of insulation of heat source portions of cigarettes sold under the trademarks "Premier" and "Eclipse" manufactured by R. J. Reynolds Tobacco Company. Thus, the "wrapping material 45" may also be referred to as the "outer wrapping paper 45" to denote such an embodiment, but without limiting the wrapping material 45 to a paper wrapping material.

The heat-generating portion 35 is preferably arranged so that one end is located at the edge of the heated portion 14 or very close to it, and is aligned in an axial direction in a sequential end-to-end arrangement with the downstream aerosol-generating portion 65. The immediate proximity of the heat-generating portion 35 to the heated portion 14 ensures direct ignition of the heat source 40 of the heat-generating portion 35.

The cross-sectional shape and dimensions of the heat-generating portion 35 prior to combustion during use may vary. Preferably, the cross-sectional area of the fuel element/heat source 40 is from about 10 percent to about 35 percent, often from about 15 percent to about 25 percent, of the total cross-sectional area of the heat-generating portion 35; while the cross-sectional area of the outer or bounding region (including the insulation 42 and associated wrapping materials 45) is from about 65 percent to about 90 percent, often from about 75 percent to about 85 percent, of the total cross-sectional area of the heat generating portion 35. For example, for a cylindrical smoking article 10 having a circumference of from about 24 mm to about 26 mm, a representative fuel element/heat source 40 has a generally circular cross-sectional shape with an outer diameter of from about 2.5 mm to about 5 mm, often from about 3 mm to about 4.5 mm.

The mouth end portion 18 of the smoking article 10 may comprise a suitable mouthpiece, such as, for example, a filter portion 55. The filter portion 55 may be positioned at one end of the aerosol generating portion 65 in such a way that the filter portion 55 and the aerosol generating portion 65 are aligned in an axial direction in an end-to-end arrangement adjacent to each other and without an insulating material between them. In one embodiment, the general cross-sectional shapes and dimensions of these portions 55, 65 are substantially identical to each other when viewed transversely to the longitudinal axis of the smoking article 10. The filter portion 55 may include a filter material 85, which may be wrapped along its longitudinally extending surface by a ficella material 90 that limits it. In one example, the filter material 85 includes a tow of plasticized cellulose acetate or other suitable cigarette-type filter material. Both ends of the filter portion 55 may be open to allow the aerosol to pass through them. In some cases, the filter portion 55 may be configured to include any combination of a paper filter body, a void, and a conventional cigarette filter material (e.g., a tow of cellulose acetate), if necessary or desired.

The filter portion 55 may also include fragrance-releasing elements. In one example, one or more breakable fragrance capsules may be included in a filter portion of the type described in U.S. Patent No. 7,479,098 to Thomas et al. and in U.S. Patent No. 7,793,665 to Dube et al. and in U.S. Patent No. 8,186,359 to Ademe et al. Additional or alternative fragrance-releasing elements may include flavored threads or delayed-release capsules that release fragrance in response to heated air passing through the filter, with or without physical manipulation by the user.

The aerosol generating portion 65 may be attached to the filter portion 55 using a bezel material 95. Examples of bezel materials are described, for example, in U.S. Patent No. 7,789,089 to Dube et al. and in U.S. Patent Application Publication No. 2007/0215167 to Crooks et al., U.S. Patent Application Publication No. 2010/0108081 to Joyce et al., U.S. Patent Application Publication No. 2010/0108084 to Norman et al. and U.S. Patent Application Publication No. 2013/0167849 to Ademe et al. and in PCT Patent Application Publication No. 2013/160671 to Dittrich et al.

The smoking article 10 may include an air diluting means, such as a plurality of perforations, each of which may pass through the rim material 95 and the ficella material 90.

The characteristic smoking article 10 has a length from about 80 mm to about 100 mm. For example, for the smoking article 10 having a length from about 85 mm, the characteristic heat-generating portion 35 can have a length from about 10 mm to about 15 mm, the characteristic aerosol-generating portion 65 can have a length from about 5 mm to about 55 mm, and the characteristic filter portion 55 can have a length from about 20 mm to about 30 mm.

A longitudinally extending, generally cylindrical aerosol generating portion 65 is located downstream of the heat generating portion 35. The aerosol generating portion 65 includes at least one aerosol generating cartridge 68 and may optionally include a tobacco rod 70. In one embodiment, at least one aerosol generating cartridge 68 is located between the heat generating portion 35 and the tobacco rod 70.

The aerosol-generating cartridge 68 includes a shell 100 configured to accommodate an aerosol precursor therein. At least a portion of the shell 100 may be perforated or may be otherwise permeable to retain the aerosol precursor within the shell with the provision of release through the perforated/permeable portion of the aerosol formed from the aerosol precursor upon heating of the shell 100 or the aerosol precursor therein. The aerosol precursor may be substantially completely consumed to obtain the aerosol as an aerosol-forming agent. Alternatively, the aerosol precursor may consist of a solid or semi-solid carrier 110 or a support in combination with an aerosol-forming agent or composition.

The use of one or more aerosol-generating cartridges 68 can provide a significant improvement over the aerosol-generating portion present in a conventional smoking article. In particular, the aerosol-generating cartridges 68 can be created offline using a cartridge-making machine. The finished cartridge 68 can then be removed from the cartridge-making machine and loaded into a smoking article assembly machine for combining with other components to form a smoking article 10. The aerosol-generating cartridge 68 is designed to provide an insert module that can be created in a large number of different variations and connected to the manufacturing process of the smoking article 10. Previously, the aerosol precursor could be included in the aerosol-generating portion during the operational manufacturing process of the smoking article, when the smoking article assembly machine performed the step of adding the aerosol precursor. The use of the aerosol-generating cartridge 68 allows avoiding the step of charging the substrate during the operational manufacturing process. The use of an aerosol generating cartridge 68 can significantly increase the speed of manufacturing the smoking article 10, especially in embodiments in which the aerosol precursor includes small particles such as beads or pellets, the current content of which in conventional smoking articles requires a slow filling process. The aerosol precursor is not limited to the form factors of beads or pellets and can include many other suitable substrates, such as chopped filler, which are described in more detail below.

The casing 100 can be made of various materials. These materials include paper, tobacco, metals and combinations thereof, such as a multilayer material. The casing 100 made of paper can be made of various papers known in the art for making smoking articles. The casing 100 made of tobacco can be made of various compositions of extruded and reconstituted tobacco sheet, which are well known in the art. In one particular embodiment, the casing 100 can be made of metal. The metal can be a thin foil. In one embodiment, a layer of thin foil is covered with a paper layer. Thus, the casing 100 can be made of well-known wrapping or wrapping materials, many of which are described in this document. In another embodiment, a metal sheet can be used to form a casing thick enough to be self-supporting when holding the carrier 110 therein. In an embodiment, the shell 100 is formed from a sheet of aluminum or stainless steel. In some embodiments, the metal sheet may have a thickness of about 12 μm to about 100 μm.

The casing 100 is shown in more detail in FIGS. 2 and 3. The casing 100 of the embodiment shown has a cylindrical shape, as shown in the perspective view of FIG. 2, having a longitudinal axis L. The cylindrical shape may be preferred if the casing 100 is used in a smoking article 10 having the shape of a conventional cigarette. The shape of the casing 100 may alternatively take other shapes, such as elongated tubular shapes with an oval, rectangular or square or other polygonal cross-section. In further embodiments, the casing 100 may not be elongated and may be cuboid or have another suitable shape.

As is better understood from the section in FIG. 3, the casing 100 of the illustrated embodiment may comprise a peripheral wall 120 having opposite first and second longitudinal ends. The longitudinal ends of the peripheral wall 120 may be defined by corresponding first and second end walls 124, respectively, extending along the first and second longitudinal ends of the peripheral wall. The first and second end walls 124 may be formed integrally with the peripheral wall 120 or otherwise attached to it. The end wall 124 may comprise a plurality of perforations 128 or may be otherwise permeable. In cases where the end wall 124 is perforated, the number, size and arrangement of the perforations 128 may be varied to control the flow of air through the casing 100 as a result of a puff on the smoking article 10 by the user. Such an end wall 124 can have any number of perforations 128 in the range from about four to about one thousand. The perforations 128 are shown as arranged in concentric circles, but can also have virtually any pattern. The perforations can be arranged in a grid of rows and columns. The perforations can be arranged along radial lines extending from the center of the end walls 124 to their periphery. The perforations can be arranged more densely near the center of the end wall 124, can be most densely arranged near the periphery of the end wall, or in some part between them. Alternatively, the perforations can be evenly spaced along the end surface (or end wall 124) of the casing 100. The perforations 128 can vary in size to control the air flow. In one example, the perforations 128 can have a diameter in the range from about 1 μm to about 1000 μm. Perforations are not limited to round holes but can take alternative shapes such as ovals, rectangles, linear slots, curved slots and the like.

In such an embodiment, the size and shape of the perforations 128 should be selected such that the aerosol precursor, which may include a solid or semi-solid carrier 110, remains contained within the shell 100 and does not have the opportunity to escape from the aerosol-generating cartridge 68 before it is sufficiently heated to form aerosols. In several embodiments, the size, shape and location of the perforations 128 are predetermined and made from the material of the end walls 124 using processes such as laser burning processes. In other embodiments, the porosity, diffusion coefficient or permeability of the material of the end walls 124 are selected so as to provide the desired containment of the aerosol precursor and air flow without changing the material specifically to create the perforations. The perforations 128 or other openings for providing air flow formed in the end wall 124a at the first end of the casing 100 do not necessarily have the same number, size, shape or arrangement of the perforations formed in the end wall 124b at the second end of the casing 100. In one embodiment, providing the end wall 124 at each end of the aerosol-generating cartridge 68 with the same design can improve manufacturing efficiency, since the cartridge will not be dependent on the direction when assembled into the smoking article 10. This arrangement can be described as providing the casing 100 with mirror symmetry about a plane that divides the casing in half between its first and second longitudinal ends. Additional manufacturing efficiency can be achieved by designing the end walls 124 and the shell 100 as a whole so that they are axisymmetric about the longitudinal axis L. In another embodiment, the end wall 124 at each end of the shell can be unique, with one end wall 124a configured to be positioned toward the heat-generating portion 35 and the other end wall 124b configured to be positioned toward the mouth end 18. Differences in the end walls 124a, 124b can change the functionality with respect to air flow in the shell 100, aerosol flow from the shell, and heat management.

In the embodiment shown in FIG. 2, the end walls 124 of the shell 100 can be formed from a first part 130 of the end wall and a second part 132 of the end wall. The first and second parts 130, 132 of the end walls can be substantially parallel to each other and offset relative to each other along the longitudinal direction L of the shell 100. The first part 130 of the end wall can extend substantially perpendicular to the distal end of the peripheral wall 120. The second part 132 of the end wall can be inserted relative to the distal end of the peripheral wall. The result of inserting the second part 132 of the end wall may be the creation of at least one pocket 140, which is recessed relative to the end plane (for example, the first part 130 of the end wall) of the aerosol-producing cartridge 68. The pocket 140 may provide a convection air gap between the heat source 40 of the heat-producing part 35 and the aerosol precursor inside the shell 100. The convection air gap created by the pocket 140 may contribute, for example, to reducing the carbonization of the aerosol precursor.

The shell 100 may be manufactured by any number of manufacturing methods. For example, a peripheral wall 120 may be initially formed. Then, one end wall 124 may be attached to the longitudinal end of the peripheral wall 120 using an adhesive, friction fit, welding, or other fastening device. The peripheral wall 120 may be formed in one piece with one of the end walls 124. The integral structure of the peripheral wall 120 and one of the end walls 124 may be created using additive manufacturing processes. After at least partially filling the chamber 150 (FIG. 3) of the shell 100 with the aerosol precursor, the aerosol-generating cartridge 68 can be completed by adding a second end wall 124b to the opposite end of the peripheral wall 120 to substantially completely enclose the aerosol precursor and provide retention of the optional carrier 110 within the chamber 150.

In one embodiment, the shell 100 includes a preformed peripheral wall 120 (for example, a tube). The tube can be made of a multilayer material of paper and foil. A metal wrapping material can be wrapped around the peripheral wall 120 with end regions extending beyond the ends of the preformed peripheral wall 120. The end regions of the wrapping material can have perforations 128 before or after wrapping around the peripheral wall. Again, the wrapping material can also be other materials that may not require perforations to achieve the desired porosity or air permeability. To cover each end of the peripheral wall, the end regions of the wrapping material can then be folded, for example, in an envelope or star shape. In one embodiment, one end of the peripheral wall 128 is closed with a folded end region of the wrapping material before adding the aerosol precursor. Then the other end of the peripheral wall is closed with a folded end region of the wrapping material after filling the chamber inside the peripheral wall with the aerosol precursor. The folded end portions of the wrapping material, which form the end walls 124, can be printed or secured with an adhesive in a folded configuration. Alternatively, after folding, the wrapping material can have sufficient plastic deformation to remain in a folded form and substantially close the end of the peripheral wall in such a way that adhesive or other fastening elements are not required. In order to facilitate the folding step, a fold line, a prestressed fracture line, a perforation line or a cut line can be formed in the wrapping material before or after the wrapping material is provided around the peripheral wall. The arrangement of the fold lines, fracture lines, and the like can be selected based on the shape of the end of the peripheral wall to be closed.

The aerosol precursor, which is configured to be placed inside the chamber 150 of the shell 100, may include a carrier 110. The carrier 110 may be a part of the aerosol precursor that does not dissolve, evaporate or otherwise substantially release from the shell 100 upon suitable heating. The carrier 110 may be selected based on elements such as its packing factor and cost to control the concentration of the generated aerosol, the cost of the product and the service life of the smoking article, often measured in puffs. The carrier 110 may have a variety of different solid or semi-solid forms and include any number of alternative aerosol-forming agents. In one example, the carrier 110 may include a reconstituted tobacco material that includes processing aids, flavoring substances and/or glycerin. The carrier and/or the aerosol-forming agent may include tobacco. More specifically, when including tobacco, the carrier may consist of a mixture of fragrant and aromatic tobaccos, for example, in the form of cut filler. These tobaccos, in turn, may be treated with an aerosol forming agent and / or at least one flavoring substance. The carrier 110 may also consist of processed tobacco (for example, reconstituted tobacco made using paper or cast sheet manufacturing processes) in the form of cut filler. Some cast sheet designs may include from about 270 mg to about 300 mg of tobacco per 10 mm of linear length of the cast sheet. In other cases, the carrier 110 may consist of a mixture of molded tobacco pellets. In particular aspects of the disclosure, the carrier 110, consisting of a form of tobacco, in turn, can be processed or processed to include an aerosol forming agent, which can include at least one flavoring substance, as well as a flame retardant (e.g., diammonium phosphate, another similar type of salt and/or other suitable flame retardant materials). The inclusion of a flame retardant material with the carrier 110 can be configured to prevent ignition of the carrier.

As used herein, the term "tobacco pellets" is intended to refer to balls, pellets or other individual small units of tobacco that have been formed, molded, compressed, extruded or otherwise brought into a desired shape. For example, tobacco pellets can be formed using a so-called marumarization process. The tobacco pellets can have smooth, regular external shapes (e.g., spheres, cylinders, ovoids, and the like) and/or they can have irregular external shapes. In one example, the diameter of each tobacco pellet can be in the range from less than about 1 mm to about 2 mm. The tobacco pellets can at least partially fill a cavity of a substrate of a smoking article, as described herein. In other words, the carrier 110 can be in the form of pellets or other loose objects that occupy a space within the shell 100 near and downstream of the heat-generating portion 35. In one example, the volume of the casing 100 can be in the range of about 500 mm ³ to about 700 mm ³ (for example, a casing in which the diameter of the cavity is from about 7.5 to about 7.8 mm, and the length of the cavity is from about 11 to about 15 mm, wherein the cavity has a generally cylindrical geometry). In one example, the mass of tobacco pellets inside the casing 100 can be in the range of about 200 mg to about 500 mg. For example, the tobacco pellets can be used to fill the casing 100 with a packing density of from about 100 to about 400 mg/cm ³ .

In one embodiment, the carrier 110 is formed by an extrusion process and may include glycerin, chopped tobacco, calcium carbonate, a binder, flavors, and water. More specifically, on a dry weight basis, the extruded material may contain about 37.86% chopped tobacco, about 39.82% calcium carbonate, about 1.00% a binder such as carboxymethyl cellulose (CMC) or cellulose gum, and about 21.32% glycerin and flavor (with ~20% glycerin).

In still other aspects, the composition of the material used for the extruded rods, namely, for example, glycerin, chopped tobacco, calcium carbonate, a binder, flavors and water, can instead be used to form a flat sheet having a thickness of about 0.3 mm to about 1.7 mm. In some cases, the sheet can also be formed by an extrusion process (or, respectively, molded or cast), wherein the sheet is then dried to form a carrier 110. The dried sheet can then be disassembled, for example, by cutting the sheet into strips or cutting the sheet into chips. The cut/cut into chips portions of the molded sheet can then be stacked or collected and placed in the casing 100 in a similar manner to tobacco in the form of cut filler (for example, placed instead of tobacco in the form of cut filler, but in a similar manner).

According to some aspects, the carrier 110 can consist of, for example, cast sheets that include tobacco material. Such cast sheets can be formed in a process in which a selected tobacco-containing mixture is cast, dried and cut into strips or cut into chips. In some cases, the cut strips or cut into chips portions of the cast sheet can be mixed with other cut fillers (for example, with traditional tobacco in the form of cut filler, with or without an additional aerosol former) to provide a desired taste and sensory perception for the user, as well as to facilitate the manufacturing process. In one example, the selected tobacco-containing mixture can be characterized as a pectin-releasing mixture comprising, for example, (on a dry weight basis) about 66.60% chopped tobacco, about 3.75% diammonium phosphate, about 4.65% ammonium hydroxide, and about 25% glycerin and flavoring. To process the pectin-releasing mixture, the chopped tobacco, diammonium phosphate, ammonium hydroxide, and water can be heated to about 160°F (71.1°C) for about 1.5 hours, for example, to improve or enhance the sensory qualities of the resulting mixture. The glycerin and flavorings can then be added to the remaining mixture after cooling following the heating step. The resulting mixture can then be used to form a cast sheet.

In another example, the selected tobacco-containing mixture can be characterized as an ammonia-free mixture comprising, for example, (on a dry weight basis) about 65.62% chopped tobacco, about 4.50% sodium alginate, about 1.13% sodium hydroxide or another pH adjuster, about 25% glycerin, and about 3.75% wood pulp. To process the ammonia-free mixture, the chopped tobacco, sodium alginate, and water can be heated to about 160°F (71.1°C) for about 1.5 hours, for example, to improve or enhance the sensory qualities of the resulting mixture. Then, hydrated wood pulp, binder, glycerin, and flavors can be added to the remaining mixture after cooling following the heating step. The resulting mixture can then be used to form a cast sheet.

In another example, the selected tobacco-containing mixture can be characterized as a tobacco-containing reconstituted material comprising, for example, (on a dry weight basis) about 51.8% tobacco pulp, about 4.2% wood pulp, about 22.0% concentrated tobacco extract, and about 22.0% glycerin and flavorings. The sheet can be formed from tobacco containing the reconstituted material in a manner similar to traditional reconstituted sheet. For example, water-soluble elements are first removed from the tobacco pulp plate and the remaining tobacco pulp is concentrated to a solids content of about 25%. Wood pulp can then be added to the tobacco pulp to form a base sheet, which can range in grammage from about 120 grams per square meter ( ^gsm ) to about 240 ^gsm . The glycerin is then mixed with a concentrated extract of tobacco-derived nicotine (TDN) (e.g., in a 1:1 ratio) and added to the base sheet. The formed base sheet may then be dried and cut into strips or shredded. Similar to cast sheets, the cut strips or shredded reconstituted sheets may be mixed with other cut fillers (e.g., traditional tobacco in the form of cut filler, with or without an additional aerosol former), (e.g., traditional tobacco in the form of cut filler, with or without an additional aerosol former).

In another example, the selected tobacco-containing mixture may be characterized as a traditional tobacco material in the form of cut filler with an increased content of glycerin. In such cases, the tobacco in the form of cut filler may contain from about 5% to about 30% glycerin or interact with it. The tobacco material in the form of cut filler with an increased content of glycerin may subsequently be used as a carrier (e.g., a base material) or may be mixed with a cast sheet material such that the resulting mixture forms a carrier and an aerosol forming agent. Depending on the amount of glycerin needed or desired, the glycerin may be applied to the tobacco in the form of cut filler, for example, as a coating for cutting (e.g., applied to individual strips of tobacco), as an additive, or both. Such tobacco in the form of cut filler with an increased glycerin content can be, for example, mixed with various cast sheets, reconstituted sheets and/or tobacco balls, if necessary or desired, to form the contents of the casing 100.

In yet another example, the selected tobacco-containing mixture can be characterized as a non-tobacco material. For example, a cast sheet used to form a carrier, an extruded carrier, or a bead-shaped (marumerized) carrier can include calcium carbonate, rice flour, a binder, diammonium phosphate, glycerin, flavors, tobacco-derived nicotine (TDN), and water. More specifically, such a non-tobacco cast sheet can consist of, for example, about 41.25% calcium carbonate, about 13.75% rice flour, about 6% ammonium alginate, about 5.5% wood pulp, about 3.5% diammonium phosphate, and about 30% glycerin. In addition, tobacco-derived nicotine (TDN), specific acids (e.g., levulinic acid and/or citric acid), and flavors can be included in glycerin. The extruded carrier or the carrier in the form of beads (marumerized) can consist, for example, of about 51.94% calcium carbonate, about 17.15% rice flour, about 1% TDN, about 1% carboxymethylcellulose (CMC), about 0.66% levulinic acid, about 0.44% lactic acid, about 20% glycerin and about 9.41% flavors. In some cases, the cast sheet can be processed to obtain cut strips, cut into chips or processed to obtain the form of cut filler. In other cases, if the carrier includes beads 110, the beads can be located inside the shell 100 so as to be adjacent to the heat-generating portion 35 or to be closest to the heat-generating portion.

In another example of a carrier formed from a non-tobacco material, tobacco derived nicotine (TDN), glycerin (e.g., an aerosol former), and flavorings may be added to an extruded ceramic substrate with a relatively high porosity (e.g., a highly porous extruded ceramic rod-shaped element). In such cases, the ceramic rod-shaped element or elements may be extruded so as to form one or more longitudinally extending channels (e.g., open channels or slits located along the outer surface, and/or passages passing through the central portion of the rod-shaped element).

The casing 100 is not limited to being filled with one type of carrier or one composition of aerosol forming agents. Any of the carriers or compositions of aerosol forming agents, including flavors and glycerin, can be located in combination within the casing 100. For example, the casing 100 can be filled with a combination of cast sheet and/or reconstituted sheet, each of which is shredded or cut into strips, mixed with tobacco in the form of cut filler treated with glycerin. The tobacco in the form of cut filler can have different levels of glycerin in a range, for example, from about 5% to about 25%. In another example, cast sheet, shredded or cut into strips, can be mixed with tobacco containing beads.

Suitable carriers, i.e., substrates, and carriers comprising aerosol forming agents (including cast sheet and reconstituted paper-type tobacco materials) are also disclosed in U.S. Patents 4,793,365 to Sensabaugh et al.; 4,893,639 to White; 5,099,861 to Clearman et al.; 5,101,839 to Jakob et al.; 5,105,836 to Gentry et al.; 5,109,122 to Clearman et al.; 5,159,942 to Brinkley et al.; 5,203,355 to Clearman et al.; #5,271,419 by Arzonico et al.; #5,327,917 by Lekwauwa et al.; #5,396,911 by Casey, III, et al.; #5,533,530 by Young et al.; #5,588,446 by Clearman; #5,598,868 by Jakob et al.; #5,715,844 by Young et al.; #6,378,528 by Beeson et al.; and #8,678,013 Crooks et al.; No. 9,149,072 to Conner et al. and U.S. Patent Application Publication No. 2005/0066986 to Nestor et al. and No. 2015/0157052 to Ademe et al. In addition, the carriers may have the types of shapes and configurations set forth in U.S. Patent No. 8,839,799 to Conner et al.; in the form of an assembled web or sheet using the types of techniques generally set forth in U.S. Patent No. 4,807,809 to Pryor et al.; or in the form of a web or sheet that is milled into a plurality of grain-direction strands using the types of techniques generally set forth in U.S. Patent No. 5,025,814 to Raker.

The components of the aerosol forming agent portion, the aerosol precursor optionally bound by the carrier 110 and configured to provide aerosols upon heating, may vary. The aerosol forming agent includes components that can be evaporated, aerosolized or entrained in air drawn through the smoking article during use. Most preferably, these components, individually or in combination, provide sensory or organoleptic effects such as taste, aroma, mouthfeel, visible aerosol sensations, and the like. Examples of components of aerosol forming agents that are drawn into the user's mouth during a puff include water (e.g., in the form of water vapor), visible aerosol forming materials (e.g., glycerin), various volatile flavors (e.g., vanillin or menthol), volatile tobacco components (e.g., nicotine), and the like.

One suitable aerosol forming agent produces a visible aerosol when sufficient heat is applied thereto or otherwise as a result of aerosol forming conditions created by the components of the smoking article. The desired aerosol forming material or agent produces a visible aerosol that can be considered "smoke-like". A suitable aerosol forming agent is chemically simple compared to the chemical nature of smoke formed by burning tobacco. One visible aerosol forming agent is a polyol, and another aerosol forming agent includes glycerin, propylene glycol, and mixtures thereof. If desired, the aerosol forming agents can be combined with other liquid materials, such as water. For example, the aerosol forming agent can include mixtures of glycerin and water or mixtures of propylene glycol and water. See, for example, the various aerosol forming materials cited in U.S. Patents 4,793,365 to Sensabaugh, Jr., et al.; 5,101,839 to Jakob, et al.; 6,779,531 to Biggs, et al.; and 8,678,013 to Crooks, et al.

The manner in which the aerosol forming agent contacts the carrier 110 (e.g., the tobacco material) can vary. The aerosol forming agent can be applied to the formed tobacco material or can be included in the processed tobacco materials during the manufacture of these materials. The aerosol forming agent can be dissolved or dispersed in an aqueous liquid or other suitable solvent or liquid carrier and sprayed onto the carrier. See, for example, U.S. Patent Application Publication No. 2005/0066986 to Nestor et al. The amount of aerosol forming agent used relative to the dry weight of the carrier can vary.

Cast sheet type materials may include relatively high levels of an aerosol forming agent. Reconstituted tobaccos produced using paper manufacturing processes may include moderate levels of an aerosol forming agent. Strip tobacco and cut filler tobacco may include lower amounts of an aerosol forming agent. Various paper and non-paper substrates including assembled, multi-layered, bimetallic/metallic, strips, beads such as alumina beads, open cell foam, foam monolith, breathable matrices and other materials may be used within the scope of the present disclosure. See, for example, U.S. Patent Nos. 5,183,062; and 5,588,446, each assigned to Clearman.

The laminated paper or other wrapping material may be constructed in accordance with the disclosure of U.S. Patent No. 6,849,085 assigned to Marton or in accordance with other suitable methods and/or materials.

In addition, various combinations and variations of flavoring agents (including various materials that alter the sensory and/or organoleptic character or nature of the mainstream aerosol of the smoking article) may be included in suitable smoking articles. The substrate material and various tobacco components of the smoking article may be treated with tobacco additives of the type commonly used in the manufacture of cigarettes, such as casings and/or topcoat components. See, for example, the types of components set forth in U.S. Patent No. 8,678,013 to Crooks et al.

FIG. 4 shows a second embodiment in which the aerosol generating portion 65 may comprise a plurality of aerosol generating cartridges 68. The contents of each shell 100 of each aerosol generating cartridge 68 may be the same or different from one to another. The differences may be manifested in differences in the carrier and/or differences in one or more components of the aerosol forming agent, the aerosol precursor. Differences in the aerosol forming agent may include differences in flavoring agents or additives themselves or in the concentration of these additives.

The aerosol precursor in each casing 100 may be selected to ensure that the thermal profile of the smoking article 10 is used. It is understood that the thermal profile of the smoking article 10 reflects that the part of the smoking article in the heat-generating part 35 is the hottest, and the part(s) at a distance from the heat source 40 are relatively cooler. Thus, in the presence of two aerosol-generating cartridges 68, the aerosol-forming agent inside the cartridge towards the mouth end 18 of the smoking article may be selected to evaporate at a lower temperature than the aerosol-forming agent in the cartridge immediately adjacent to the heat-generating part 35.

In other embodiments, the shell 100 of the aerosol-generating cartridge 68 may itself be subdivided into sub-compartments. The carrier and/or portion of the aerosol-generating agent in each sub-compartment may vary. The sub-compartments may be arranged sequentially along an axis intended to pass between the heated portion 14 and the mouth-end portion 18 of the smoking article 10. In other embodiments, the sub-compartments may be arranged parallel along the length of the shell 100.

The dividing walls between the sub-compartments, extending both along and across the longitudinal axis of the shell 100, can be formed from similar materials as the peripheral wall 120 and the end walls 124 (for example, paper, tobacco, metal foil or combinations and multilayer materials thereof). The materials forming the dividing walls can have a porosity, a diffusion coefficient and/or permeability to facilitate a desired air flow through the aerosol-generating cartridge 68 when a user puffs.

The above-described components of the aerosol generating portion 65, including at least one aerosol generating cartridge 68 and an optional tobacco rod 70, can be located within the wrapping material 160 or limited by it. The wrapping material 160 can be configured to facilitate the transfer of heat from the heated part 14 of the smoking article 10 (for example, from the heat generating portion 35) to the components of the aerosol generating portion 65. In other words, the aerosol generating portion 65 and the heat generating portion 35 can be configured to exchange heat with each other, and such heat exchange relationship can be facilitated by the wrapping material 160, which limits both the heat generating portion 35 and the aerosol generating portion 65 to form a subassembly. The heat exchange ratio is such that sufficient heat is supplied from the heat source 40 to the aerosol generating portion 65 to volatilize/aerosolize the aerosol forming agent to form and generate the aerosol. In some cases, the wrapping material 160 may be a separate component with respect to the outer wrapping material 45 or may interact with the outer wrapping material 45 in various ways. In other cases, the wrapping material 160 may comprise an insulating material for insulating the aerosol generating cartridge 68 from the outer wrapping material 45. For example, the wrapping material 160 may comprise a glass mat having a thickness of about 50 μm to about 500 μm.

In one embodiment of the disclosure of the present invention, the heat exchange ratio is provided by sequentially arranging the heat generating portion 35 and the aerosol generating portions 65 adjacent to each other. In some cases, these segments can be sequentially arranged so that they contact each other "end-to-end". The heat exchange ratio can also be provided by extending a heat-conducting material from the region of the heat source 40 into the region occupied by the aerosol generating portion 65 and/or around it. For example, in one embodiment, the characteristic wrapper material 160 can include heat-conducting elements or properties for transferring heat from the heat generating portion 35 to the aerosol generating portion 65 (and/or maintaining heat interaction with the aerosol generating portion 65 along its length) to provide aerosolization of aerosol forming agents contained at least inside the aerosol generating cartridge. In other embodiments, the characteristic wrapping material 160 and/or the outer wrapping material 45 may have thermally conductive properties for dissipating heat that is not directed from the heat-generating portion 35 to the aerosol-generating portion 65 and/or for uniformly and more completely distributing heat between the heat-generating portion 35 and the aerosol-generating portion 65 while ensuring aerosolization of the aerosol-forming agents contained at least in the shell 100 of the aerosol-generating cartridge 68. Such a wrapping material 160 may be provided with a multi-layer paper/foil sheet, for example, consisting of an outer layer of a sheet of paper-type material and an inner layer of a sheet of thermally conductive metal foil. A sheet of metal foil forming the inner layer may, for example, extend from a region downstream of the heat source 40 and along at least part of the length of the aerosol-producing portion 65. The multilayer material of the metal foil/inner layer may be bonded to the outer layer in the form of one or more separate longitudinally extending strips attached to the outer layer, or in the form of a continuous sheet that interacts with the outer layer to limit said region overlapping the heat-producing and aerosol-producing portions 35, 65.

In embodiments in which the wrapping material 160 is selected for thermal conductivity, the wrapping material in the form of a multi-layer paper/foil sheet may have a typical length (e.g., along the aerosol-generating portion 65) from about 8 mm to about 50 mm for a representative smoking article of the type described herein. The multi-layer paper/foil sheet may be perforated, etched, embossed, or primed, for example, to facilitate manufacture. In some cases, the thickness of the foil used in the multi-layer material may be varied or increased/decreased as needed or desired, for example, from about 0.0001 inches to 0.005 inches (from 0.00254 mm to 0.127 mm), in order to change the characteristics of the multi-layer paper/foil sheet and/or reduce visual scorching of a portion of the paper sheet of the multi-layer material and/or the outer wrapping paper 45.

The multilayer paper/foil sheet of the wrapping material 160 can be formed in various ways. For example, a thermally conductive ink (in some cases a thermally conductive metallic ink) can be used to print on the paper portion, so that the printing ink forms a foil layer (sheet or strip) on the paper portion (and/or can be at least partially absorbed/combined with the paper portion). Such thermally conductive ink can include, for example, carbon, graphite, graphene, silver or any other suitable thermally conductive or thermally conductive material or combinations thereof to conduct heat along the paper portion, wherein the conducted heat, in turn, heats the aerosol-generating cartridge to generate an aerosol from it. In one embodiment, the thermally conductive ink may be printed in a continuous pattern or a discontinuous pattern on foil sheets or regular cigarette paper with a cigarette paper grammage in the range of from about 20 g/ ^m2 to about 100 g/ ^m2 .

In other cases, a heat- or thermally conductive material, such as, for example, a metal foil (for example, silver), a conductive carbon material (for example, graphene) or any other suitable heat-conductive material or combinations thereof can be applied to or otherwise attached in various configurations (for example, a separate strip, a full sheet, a full coating, and the like) to a conventional cigarette paper, for example, using an "island placement" technology or a selective deposition/bonding technology, for example, to facilitate manufacturing and improve functionality. In any case, the use of a multi-layer paper/foil sheet as a wrapping material 160 can in some cases dissipate or redirect the heat generated by the heat-generating portion 35 to reduce the burning of the outer wrapping paper 45 and/or other components of the smoking article 10. Thus, eliminating the burning can improve the taste and sensory perception of the generated aerosol for the user.

In other embodiments, the wrapping material 160 may comprise a three-layer sheet comprising a layer of cigarette paper, a foil layer and a layer of tobacco packaging paper. The composition of the tobacco packaging paper layer may vary and may consist of and include various proportions of, for example, burley tobacco, flue-cured tobacco, oriental tobacco or any other suitable type of tobacco or a combination thereof. The inclusion of tobacco in the tobacco packaging paper layer may be up to about 85% tobacco, and the tobacco packaging paper layer may have a grammage in the range of about 20 g/m ² to about 100 g/m ² . In some cases, the three-layer form of the wrapping material 160 may consist of tobacco packaging paper/foil/tobacco packaging paper, as needed or desired. In other cases, a dual-layer tobacco packaging paper/foil material may be implemented, wherein the tobacco sheet may be applied to an aluminum or other heat-conducting foil having a thickness in the range of from about 0.0005 inches to about 0.002 inches (from 0.0127 mm to 0.0508 mm), wherein such dual-layer sheet may have a grammage of from about 60 g/ ^m2 to about 100 g/ ^m2 .

According to still other additional embodiments, the wrapping material 160 can be made in the form of any of a multilayer material of paper sheets and foil, a multilayer material of paper sheets, foil and paper, a multilayer material of paper sheets, foil and tobacco, a non-woven graphite sheet, a composite sheet of non-woven graphite and graphene, a graphene sheet, a multilayer material of graphene sheets and foil, a multilayer material of graphene sheets, foil and paper, a multilayer material of paper sheets and graphene, graphene ink printed on a paper sheet, graphene ink printed on a foil sheet, carbon nanotubes interacting with a paper sheet or a foil sheet, fullerenes interacting with a paper sheet or a foil sheet, or graphene interacting with a paper sheet or a foil sheet. In such cases, for example, when graphene comprises one of the outer layers of the multilayer material, it may be desirable for the graphene layer of the multilayer material to provide the initial layer of the multilayer material closest to the aerosol-generating cartridge 68. In other cases, for example, in the case of a multilayer material made of graphene sheets and foil, it may be desirable for the foil sheet layer of the multilayer material to provide the initial layer of the multilayer material closest to the aerosol-generating cartridge 68, while the graphene layer acts as a heat shield between the aerosol-generating cartridge 68 and the outer wrapper material 45, or the order may be reversed, where the graphene layer of the multilayer material is the initial layer of the multilayer material closest to the aerosol-generating cartridge 68, while the foil sheet layer acts as a heat shield between the aerosol-generating cartridge 68 and the outer wrapper material 45. In cases where the wrapper material 160 comprises a heat-conducting layer and a paper sheet or a foil sheet, between which an insulating layer or a thermal layer may be located.

In embodiments comprising an imprint of, for example, graphene ink, the ink may be applied using various printing processes, such as, for example, gravure printing, flexographic printing, offset printing, screen printing, inkjet printing or other suitable printing method, to provide various thicknesses, patterns, surface coverage and composition gradients.

The outer wrapping paper 45 is typically configured to wrap around the heat-generating portion 35 and extend in the longitudinal direction (downstream) to also wrap around the aerosol-generating portion 65 and along at least a portion of its length. While interacting in such a way as to be wrapped around the said components of the smoking article 10, the outer wrapping paper 45 also extends at the interface between the heat-generating portion 35 and the aerosol-generating portion 65. In some embodiments, the outer wrapping paper 45 may be treated, may interact with or otherwise be exposed to, for example, calcium carbonate (CaCO3), aluminum hydroxide, magnesium hydroxide and/or combinations thereof as fillers in the paper matrix of the outer wrapping material 45 at least as anti-burning agents.

It will be understood by a person skilled in the art that the wrapping material 160 and/or the outer wrapping material 45, when wrapped around the respective components of the smoking article, may have their opposite ends (for example, the ends overlapping at an angle, forming a longitudinally extending seam along the smoking article) sealed to each other, for example, using an adhesive material. Accordingly, in some embodiments of the present invention, the adhesive material may also include a filler, such as, for example, calcium carbonate (CaCO3), aluminum hydroxide, magnesium hydroxide and/or combinations thereof to reduce, minimize or prevent burning or charring of the adhesive material and/or the outer wrapping material 45 along the longitudinally extending seam of the outer wrapping material 45 wrapped around the components of the smoking article.

Additional methods and techniques for assembling representative types of smoking articles are disclosed in U.S. Patents 5,469,871 to Barnes et al. and 8,678,013 to Crooks et al.; 9,149,072 to Conner et al.; and U.S. Patent Application Publication Nos. 2012/0042885 to Stone et al.; 2014/0261470 to Amiss et al.; and 2015/0157052 to Ademe et al.

In some embodiments, both ends of the aerosol generating portion 65 are open to expose at least one aerosol generating cartridge thereof. Together, the heat generating portion 35 and the aerosol generating portion 65 form an aerosol generating subassembly 170. The aerosol generating portion 65 is located near the downstream end of the aerosol generating portion 35 such that these portions are aligned in an axial direction in an end-to-end arrangement. These portions may abut one another or may be located at a small distance, which may include an optional buffer region created by a pocket 140 in the end wall 124 of the casing 100. The external cross-sectional shapes and dimensions of these portions, when viewed transversely to the longitudinal axis of the smoking article 10, may be substantially identical to one another. The physical arrangement of these components is preferably such that heat is transferred (e.g. by mechanisms that include conductive or convective heat transfer) from the heat source 40 to the aerosol precursor during the time of actuation of the heat source (e.g. ignition) during use of the smoking article 10.

As noted above, one or more pockets 140 may reduce potential scorching or other thermal degradation of portions of the aerosol generating portion 65. Other thermal buffers may also be provided by regions that are partially or substantially completely filled with a non-combustible material, such as, for example, a metal, organic, inorganic, ceramic or polymeric materials, or any combination thereof. The thickness (length) of the buffers may be from about 1 mm to about 10 mm, but often the thickness (length) will be from about 2 mm to about 5 mm. If desired, the buffers may include catalytic materials, such as materials comprising sulfur or copper ions or oxides and/or salts of sulfur and copper ions. See, for example, U.S. Patent No. 8,469,035 to Banerjee et al.; No. 8,617,263 by Banerjee et al. and No. 9,220,301 by Banerjee et al.

The smoking articles 10 described with reference to FIGS. 1-4 can be used in much the same way as cigarettes that have been sold under the trademarks "Premier", "Revo" and "Eclipse" manufactured by R. J. Reynolds Tobacco Company and "Steam Hot One" manufactured by Japan Tobacco Inc. In other words, the fuel element or heat source 40 is ignited by a match or a cigarette lighter. The ignited fuel element/heat source resulting from such ignition generates heat, which is transferred to the aerosol generating cartridge 68 in the aerosol generating portion 65. The aerosol precursor, including aerosol forming agents, as well as flavors and tobacco components, are heated and volatilized/aerosolized while inside the casing 100, to form an aerosol. This aerosol is captured by the drawn air and drawn through the filter portion 55 into the user's mouth.

FIG. 5 schematically shows another embodiment of the disclosure of the present invention. Where FIGS. 1-4 show an embodiment of a smoking article 10 configured to generate heat by igniting a heat source 40, the smoking article 300 of FIG. 5 is configured to use electrical energy to generate heat to facilitate the formation of an inhalable substance. Examples of devices are described in U.S. application SN No. 15/799,365 to Sebastian, filed October 31, 2017, which is incorporated herein by reference in its entirety. The smoking article 300 may also be characterized as a vapor-generating article or a drug delivery article. Thus, such articles or devices may be adapted to deliver one or more substances (e.g., flavors and/or pharmaceutical active ingredients) in an inhalable form or state. For example, the inhalable substances may be substantially in the form of a vapor (e.g., a substance that is in the gaseous phase at a temperature below its critical point). Alternatively, the inhalable substances may be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). For simplicity, the term "aerosol" as used in this application is intended to refer to vapors, gases, and aerosols of a form or type that are suitable for inhalation by humans, whether or not they are visible and whether or not they have a form that can be considered "smoke-like."

In some embodiments, the smoking article 300 may include a control body 310 and an element 320 in the form of an aerosol source. The control body 310 may be reusable, while the element 320 in the form of an aerosol source may be configured to allow a limited number of uses and/or configured to allow a single use. In various embodiments, the element 320 in the form of an aerosol source includes an aerosol precursor contained inside a shell, forming an aerosol-generating cartridge 368. For heating the element 320 in the form of an aerosol source, in particular, the aerosol precursor in it, at least a part of the heating device may be located in a receiving socket provided in the control body 310. The heating device may generate heat using an electric current applied by one or more power sources, which may be rechargeable or replaceable. The heating device may be a resistive heater or an induction heater. When using an induction heater, both the resonant transmitter and the resonant receiver can be substantially permanently located in the control housing 310. In other embodiments, the resonant receiver can be provided as part of the aerosol source element 320. The resonant receiver can be a dedicated component of the aerosol source element 320, or the resonant receiver function can be performed by the aerosol-generating cartridge 368 of the aerosol source element.

FIG. 5 shows a smoking article 300 according to an embodiment of the present invention. The smoking article 300 may include a control body 310 and an aerosol source element 320. In various embodiments, the aerosol source element and the control body may be aligned to provide the ability to operate permanently or with the ability to detach. In this regard, FIG. 5 shows the smoking article 300 in a connected configuration. Various mechanisms may connect the aerosol source element 320 and the control body 310, such as a threaded interaction, a tight fit interaction, an interference fit, a sliding fit, a magnetic interaction, or the like. In various embodiments, the control body 310 of the smoking article 300 may be substantially rod-shaped, substantially tubular in shape, substantially cylindrical in shape, or the control body may take another portable shape, such as the shape of a small box.

In specific embodiments, the control body 310 and/or the aerosol source element 320 may be referred to as disposable or reusable. For example, the control body 310 may have a replaceable battery or a rechargeable battery, a solid-state battery, a thin-film solid-state battery, a rechargeable supercapacitor, or the like, and thus be combined with any type of recharging technology, including connection to a conventional wall charger, connection to a car charger (e.g., a cigarette lighter socket), connection to a computer, such as via a universal serial bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB type C), connection to a photovoltaic cell (sometimes referred to as a solar cell) or to a solar panel of solar cells or a wireless radio frequency (RF) charger. Additionally, in some embodiments, the aerosol source element 320 may comprise a disposable device.

In various embodiments of the present invention, the aerosol source element may comprise a heated end 314 that is configured to be inserted into the control body 310 and a portion 318 of the mouthpiece end on which the user draws to generate an aerosol. The heated portion 314 may denote any portion of the aerosol source element that is inserted into the control body 310. The heated portion is not limited to the distal tip or end end of the aerosol source element. Some or all of the heated portion 314 may receive heat from the control body 310. Alternatively, some or all of the heated portion 314 may be configured to generate heat in the presence of eddy currents. In various embodiments, the heated portion 314 may include an aerosol precursor contained within the aerosol-generating cartridge 368. In other embodiments, the aerosol-generating cartridge 368 may be located outside the control housing 310, in whole or in part, when the aerosol source element cooperates with the control body. The aerosol-generating cartridge 368 may include a shell and an aerosol precursor corresponding to any embodiment of the aerosol-generating cartridge 68 for use in the smoking article 10 described above and shown in FIGS. 1-4.

In various embodiments, the mouth end portion 318 of the aerosol source element 320 may comprise a filter portion 355, which may be made of cellulose acetate or polypropylene material. In various embodiments, the filter portion 355 may increase the structural integrity of the mouth end portion of the aerosol source element 320 and/or provide filtering capability, if desired, and/or provide draw resistance. For example, an article according to an embodiment of the present invention may exhibit a pressure drop of from about 50 mm to about 250 mm of water pressure drop at 17.5 cm ³ per secondary air flow. In additional embodiments, the pressure drop may be from about 60 mm to about 180 mm or from about 70 mm to about 150 mm. The pressure drop can be measured using a Filtrona filter test station (CTS series), available from Filtrona Instruments and Automation Ltd, or a Quality Test Module (QTM), available from Cerulean Division of Molins, PLC. The thickness of the filter portion along the length of the mouth end portion 318 of the aerosol source element 320 can vary - for example, from about 2 mm to about 20 mm, from about 5 mm to about 20 mm, or from about 10 mm to about 15 mm. In some embodiments, the filter portion 355 can be held in place by an outer wrapping material. The outer wrapping material can correspond to the outer wrapping material 45, 95 and 160 described above for connecting at least one aerosol generating cartridge 368 to the filter portion 355.

Examples of the types of overwrap materials, overwrap components, and processed overwrap materials that can be used in the overwrap of the present invention are described in U.S. Patents 5,105,838 to White et al.; 5,271,419 to Arzonico et al.; 5,220,930 to Gentry; 6,817,365 to Hancock et al.; 6,908,874 to Woodhead et al.; 6,929,013 to Ashcraft et al.; 7,195,019 to Hancock et al.; 7,216,652 to Fournier et al.; No. 7,276,120 to Holmes and No. 7,275,548 to Hancock et al., which are incorporated herein by reference in their entireties. Representative wrapping materials are commercially available as R. J. Reynolds Tobacco Company grades 119, 170, 419, 453, 454, 456, 465, 466, 490, 525, 535, 557, 652, 664, 672, 676, and 680 from Schweitzer-Maudit International. The porosity of the wrapping material can vary and often ranges from about 5 CORESTA units to about 30,000 CORESTA units, often from about 10 CORESTA units to about 90 CORESTA units, and often from about 8 CORESTA units to about 80 CORESTA units.

In order to maximize the delivery of aerosol and flavoring that may otherwise be diluted by radial (e.g., outward) filtration of air through the outer wrapping material, one or more layers of non-porous cigarette paper may be used to wrap the aerosol source element (with or without the presence of the outer wrapping material). Examples of suitable non-porous cigarette papers are commercially available from Kimberly Clark Corp. as KC 63 5, P878 5, P878 16 2 and 780 63 5. Preferably, the outer wrapping material is a material that is substantially impermeable to vapor generated during use of the smoking article 300. If desired, the outer wrapping material may comprise a resilient cardboard material, foil-clad cardboard, metal, polymeric materials or the like, and this material may be surrounded by a cigarette wrapping paper. The outer wrapping material may comprise tipping paper that surrounds the component and may optionally be used to attach the filter material to the aerosol source element, which is also described herein.

In one example, the control body 310 facilitates the generation of heat with the induction heater 340. The induction heater 340 includes a resonant transformer containing a resonant transmitter and a resonant receiver. In particular, the control body 310 can contain a casing 342 that includes an opening 344 formed at its interacting end, a flow sensor (for example, a puff sensor or a pressure switch), a control component 346 (for example, a microprocessor, which itself is a microcontroller or represents a part thereof, a printed circuit board (PCB) that contains a microprocessor and/or a microcontroller, the like), a power source 348 (for example, a battery that can be rechargeable, and/or a rechargeable supercapacitor) and an end cap that can contain an indicator 350 (for example, a light-emitting diode (LED)).

Examples of power sources are described in U.S. Patent No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017/0112191 to Sur et al., filed October 21, 2015, the disclosures of which are incorporated herein by reference in their respective entireties. With respect to the flow sensor, typical current regulating components and other current controlling components, including various microcontrollers, sensors, and switches for aerosol delivery devices, are described in U.S. Patent No. 4,735,217 to Gerth et al.; U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,875, all to Brooks et al.; in U.S. Patent No. 5,372,148 to McCafferty et al.; in U.S. Patent No. 6,040,560 to Fleischhauer et al.; in U.S. Patent No. 7,040,314 to Nguyen et al.; and in U.S. Patent No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entireties. Reference is also made to various control circuits described in U.S. Patent No. 9,423,152 to Ampolini et al., which is incorporated herein by reference in its entirety.

In one embodiment, the indicator 350 may comprise one or more light-emitting diodes, quantum dot light-emitting diodes, or the like. The indicator 350 may be communicatively coupled to the control component 346 and may illuminate, for example, during a user's puff through the aerosol source element 320 when coupled to the control body 310, which is detected by the flow sensor.

In the proposed smoking article of the present embodiment, other additional components may be used. For example, U.S. Patent No. 5,154,192 to Sprinkel et al. discloses indicators for smoking articles; U.S. Patent No. 5,261,424 to Sprinkel Jr. discloses piezoelectric sensors that can be formed at the mouthpiece end of the device to detect the user's lip activity associated with performing a puff, with the subsequent initiation of heating of the heating device; U.S. Patent No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling the flow of energy in a heat load array in response to the resistance to puffing of the mouthpiece; U.S. Patent No. 5,967,148 to Harris et al. discloses receptacles in a smoking device that include an identifier that detects a discontinuity in the infrared transmittance of an inserted component and a controller that executes a detection program when the component is inserted into the receptacle; U.S. Patent No. 6,040,560 to Fleischhauer et al. describes a specific executable power cycle with multiple differential phases; U.S. Patent No. 5,934,289 to Watkins et al. discloses photonic optoelectronic components; U.S. Patent No. 5,954,979 to Counts et al. discloses means for varying the draw resistance through a smoking device; U.S. Patent No. 6,803,545 to Blake et al. discloses certain battery configurations for use in smoking devices; U.S. Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Patent No. 8,402,976 to Fernando et al. discloses computer communication means for smoking devices for facilitating charging and allowing automated control of the device; U.S. Patent No. 8,689,804 to Fernando et al. discloses identification systems for smoking devices; and PCT Patent Application Publication No. WO 2010/003480 to Flick discloses a fluid flow sensing system indicating the presence of a puff in an aerosol generation system; the disclosures of each of the foregoing inventions being incorporated herein by reference in their entirety.

Further examples of components related to electronic smoking articles and disclosing materials and components that may be used in the present article are described in U.S. Patents Nos. 4,735,217 to Gerth et al.; 5,249,586 to Morgan et al.; 5,666,977 to Higgins et al.; 6,053,176 to Adams et al.; 6,164,287 to White; 6,196,218 to Voges; 6,810,883 to Felter et al.; 6,854,461 to Nickols; 7,832,410 to Hon; #7,513,253 by Kobayashi; #7,896,006 by Hamano; #6,772,756 by Shayan; #8,156,944 and #8,375,957 by Hon; #8,794,231 by Thorens et al.; #8,851,083 by Oglesby et al.; #8,915,254 and 8,925,555 by Monsees et al.; #9,220,302 by DePiano et al.; U.S. Patent Application Publication Nos. 2006/0196518 and 2009/0188490 to Hon; U.S. Patent Application Publication No. 2010/0024834 to Oglesby et al.; U.S. Patent Application Publication No. 2010/0307518 to Wang; PCT Patent Application Publication WO 2010/091593 to Hon; and PCT Patent Application Publication WO 2013/089551 to Foo, each of which is incorporated herein by reference in its entirety. Additionally, U.S. Patent Application Publication No. 2017/0099877 to Worm et al. discloses capsules that can be included in smoking articles and configurations for keychain smoking articles and is incorporated herein by reference. Various materials disclosed in the above-mentioned documents may be incorporated into the present devices in various embodiments, and all of the above disclosures are incorporated herein by reference in their entirety.

The control body 310 of the embodiment shown in FIG. 5 comprises a resonant transmitter and a resonant receiver, which together form a resonant transformer. It should be noted that the resonant transformer of various embodiments of the present invention can take various forms, including embodiments in which the resonant transmitter and/or the resonant receiver are located substantially permanently in the control body 310 of the smoking article 300.

In a particular embodiment shown in FIG. 5, the resonant transmitter comprises a multilayer material that includes a foil material 360 that surrounds a supporting cylinder 361, and the resonant receiver of the embodiment shown comprises a plurality of receiver contacts 362 that extend from a main receiver element 364. In some embodiments, the foil material may include an electrical path printed thereon, such as, for example, one or more electrical paths that may, in some embodiments, form a helical structure when the foil material is located around the resonant receiver. In various embodiments, the resonant receiver and the resonant transmitter may be made of one or more conductive materials, and in additional embodiments, the resonant receiver may be made of a ferromagnetic material, including, without limitation, cobalt, iron, nickel, and combinations thereof. In the embodiment shown, the foil material 360 is made of a conductive material, and the contacts 362 of the receiver are made of a ferromagnetic material. In various embodiments, the main element 364 of the receiver can be made of a non-conductive and/or insulating material.

As shown in the drawing, the resonant transmitter 360 can extend near the end for interaction of the housing 342 and can be configured to substantially surround a portion of the heated portion 314 of the element 320 in the form of an aerosol source, which includes an aerosol-generating cartridge 368. Thus, the resonant transmitter 360 of the shown embodiment can form a tubular configuration. As shown in FIG. 5, the resonant transmitter 360 can surround the supporting cylinder 361. The supporting cylinder 361 can form a tubular configuration and can be configured to provide support for the foil material 360 in such a way that the foil material 360 does not come into contact with the contacts 362 of the resonant receiver and, thus, does not lead to a short circuit with them. Thus, the supporting cylinder 361 may comprise a non-conductive material, which may be substantially transparent to the oscillating magnetic field generated by the foil material 360. In various embodiments, the foil material may be embedded in the supporting cylinder or otherwise connected to it. In the illustrated embodiment, the foil material 360 interacts with the outer surface of the supporting cylinder 361; however, in other embodiments, the foil material may be located on the inner surface of the supporting cylinder or be completely embedded in the supporting cylinder.

In the illustrated embodiment, the support cylinder 361 may also facilitate the proper positioning of the aerosol source element 320 when the aerosol source element is inserted into the housing 342. In particular, the support cylinder 361 may extend from the opening 344 of the housing 342 to the main receiver element 364. In the embodiment shown, the inner diameter of the supporting cylinder 361 may be slightly larger than the outer diameter of the corresponding element 320 as an aerosol source or approximately equal to it (e.g. to create a sliding fit) such that the supporting cylinder 361 guides the element 320 as an aerosol source into the proper position (e.g. a lateral position) relative to the control housing 310. In the embodiment shown, the control housing 310 is designed such that, when the element 320 as an aerosol source is inserted into the control housing, the contact 362 of the receiver is located in approximately the radial center of the heated end 314 of the element 320 as an aerosol source.

In various embodiments, the carrier element 361 of the transmitter can interact with the inner surface of the housing 342 to ensure the alignment of the carrier element with respect to the housing. Thus, as a result of the tight connection between the carrier element 361 and the resonant transmitter 360, the longitudinal axis of the resonant transmitter can extend substantially parallel to the longitudinal axis of the housing 342. In various embodiments, the resonant transmitter 360 can be located without contact with the housing 342 to avoid transmitting current from the connecting device of the transmitter to the outer housing. In some embodiments, insulation can be located between the resonant transmitter 360 and the housing 342 to prevent contact between them. As can be understood, the insulation and the carrier element can comprise a non-conductive material, such as an insulating polymer (for example, plastic or cellulose), glass, rubber, ceramics and porcelain. Alternatively, the resonant transmitter may be in contact with the housing in embodiments in which the housing is formed from a non-conductive material such as plastic, glass, rubber, ceramic, or porcelain.

In some embodiments, the aerosol-generating cartridge 368 may be made at least partially of conductive or ferromagnetic materials to function as a resonant receiver. For example, as discussed above, the shell of the aerosol-generating cartridge 368 may be made of aluminum or another metallic material that may be suitable for functioning as a resonant receiver. Additionally or alternatively, the carrier or other component of the aerosol precursor within the shell may be made of a material suitable for use as a resonant receiver, such as made of a material that generates heat in the presence of an alternating magnetic field generated by a resonant transmitter. In other embodiments, the wrapping material 45, 95 used to assemble the element 320 as an aerosol source may comprise at least a portion thereof, such as a foil layer, that is suitable for functioning as a resonant receiver. In additional embodiments, a specialized resonant receiver component is attached to the aerosol-generating cartridge 368 when forming the aerosol source element 320. Unlike the illustrated embodiment of FIG. 5, in which the resonant receiver comprises contacts 362 formed as part of the control housing 310, each of the variations described above implements the resonant receiver as part of the aerosol source element 320 for removal from the opening 344 when the aerosol-generating agent has run out in the aerosol source element 320.

As indicated above, the aerosol source elements 320 of the present invention are configured to work together with the control housing 310 to produce an aerosol. In particular, when the aerosol source element 320 is connected to the control housing 310 (for example, when the aerosol source element is inserted into the control housing), the resonant transmitter can at least partially surround, can substantially surround, or can completely surround the resonant receiver (for example, by passing along its circumference). In addition, the resonant transmitter can extend along at least a part of the longitudinal length of the resonant receiver, can extend along most of the longitudinal length of the resonant receiver, or can extend substantially along the entire longitudinal length of the resonant receiver or beyond it. Furthermore, in various embodiments, when the aerosol source element is inserted into the control housing, the resonant receiver may extend at least a portion of the longitudinal length of the aerosol generating portion 365, may extend along a major portion of the longitudinal length of the aerosol generating portion, or may extend along substantially the entire longitudinal length of the aerosol generating portion or beyond.

In use, when the user puffs on a portion of the mouthpiece end of the element 320 as an aerosol source, the resonant transmitter can thus generate an oscillating magnetic field. As a result of placing the resonant receiver inside the region formed by the resonant transmitter, the resonant receiver can be subjected to the oscillating magnetic field generated by the resonant transmitter. In particular, the resonant transmitter and the resonant receiver together form a resonant transformer. In some examples, the resonant transformer and associated circuits including an inverter can be configured to operate in accordance with a suitable wireless power transmission standard, such as the Qi interface standard developed by the Wireless Power Consortium (WPC), the Power Matters Alliance (PMA) interface standard developed by the PMA, the Rezence interface standard developed by the Alliance for Wireless Power (A4WP), and the like.

According to embodiment examples, a change in the current in the resonant transmitter, directed to it from the power source by means of the control component, can create an alternating electromagnetic field, which penetrates the resonant receiver, thereby generating electric eddy currents inside the resonant receiver. The alternating electromagnetic field can be obtained by directing an alternating current to the resonant transmitter. As indicated above, in some embodiments, the control component can comprise an inverter or inverter circuit, made or made with the possibility of converting direct current, supplied by the power source, into alternating current, supplied to the resonant transmitter.

Eddy currents flowing in the material forming the resonant receiver can heat the resonant receiver due to the Joule effect, and the amount of heat generated is proportional to the square of the electric current multiplied by the electrical resistance of the resonant receiver material. In embodiments of the resonant receiver containing ferromagnetic materials, heat can also be generated due to magnetic hysteresis losses. Several factors contribute to an increase in the temperature of the resonant receiver, including, without limitation, proximity to the resonant transmitter, magnetic field distribution, electrical resistance of the resonant receiver material, saturation magnetic induction, skin effects or skin depth, hysteresis losses, magnetic susceptibility, magnetic permeability, and dipole moment of the material.

In this regard, the resonant receiver and the resonant transmitter may comprise an electrically conductive material. As an example, the resonant transmitter and/or the resonant receiver may comprise various conductive materials, including metals such as copper and aluminum, alloys of conductive materials (e.g., diamagnetic, paramagnetic or ferromagnetic materials) or other materials such as ceramics or glass with one or more conductive materials embedded therein. In another embodiment, the resonant receiver may comprise conductive particles. In some embodiments, the resonant receiver may be coated with a thermally conductive passivation layer or otherwise comprise it (e.g., a thin layer of glass).

Accordingly, in various embodiments, the resonant receiver can be heated by the resonant transmitter. The heat generated by the resonant receiver can heat the aerosol precursor while the aerosol precursor is inside the aerosol-generating cartridge 368 so that an aerosol is formed inside the cartridge. By placing the resonant receiver near the aerosol precursor and at a substantially equal distance from it, the aerosol precursor can be substantially uniformly heated.

The aerosol may be mixed with air supplied through vents/inlets that may be provided in the housing of the control body. For example, in some embodiments, the vents may be formed around the periphery of the housing upstream of the heated end of the aerosol source element. Accordingly, the air and aerosol mixture may be directed toward the user. For example, the air and aerosol mixture may be directed toward the user through a filter at the mouth end of the aerosol source element. However, as can be understood, the flow pattern through the smoking article may differ from the specific configuration described above in any of a variety of ways without departing from the scope of the present invention.

In some embodiments, the aerosol source element may also comprise an authentication component that may be configured to authenticate the aerosol source element. Thus, for example, the control component may direct current to the resonant transmitter only when the aerosol source element is authenticated. In some embodiments, the authentication component may comprise a radio frequency identification (RFID) chip configured to wirelessly transmit a code or other information to the control body. In this way, the smoking article may be used without the need for electrical connectors to interact between the aerosol source element and the control body. In addition, various examples of control components and the functions performed by these components are described in U.S. Patent No. 9,854,841 to Ampolini et al., which is incorporated herein by reference in its entirety.

As indicated above, in some embodiments, the control component of the control body may comprise an inverter or an inverter circuit configured or configured to convert direct current supplied by the power source into alternating current supplied to the resonant transmitter. The inverter may also include an inverter controller implemented as an integrated circuit and configured to output a signal configured to excite the resonant transmitter in order to generate an oscillating magnetic field and to induce an alternating voltage in the resonant receiver when exposed to the oscillating magnetic field. This alternating voltage causes the resonant receiver to generate heat and, thereby, to create an aerosol from the aerosol-forming agent.

In some examples, the control housing may further protect against the temperature of the resonant receiver reaching or exceeding a threshold temperature. In some of these examples, the control component may include a microprocessor configured to receive a measurement of an alternating current induced in the resonant receiver. The microprocessor may then control the operation of at least one functional element of the smoking article in response to the measurement to reduce the temperature of the resonant receiver in cases in which the measurement indicates a temperature equal to or above the threshold temperature. One method for reducing the temperature may be to reduce, modulate and/or stop the current supplied to the resonant transmitter. Some examples are described in U.S. Patent Application Publication No. 2017/0196263 to Sur, which is incorporated herein by reference in its entirety.

Additional examples of various inductive control components and associated circuits are described in U.S. Patent Application Publication Nos. 2017/0202266 and 2018/0132531 to Sur et al., each of which is incorporated herein by reference in its entirety.

In light of the possible interrelations between aspects of the present invention in providing the noted advantages and benefits associated with it, the present invention therefore specifically and expressly includes, without limitation, embodiments representing various combinations of the disclosed aspects. Thus, the disclosure of the present invention includes any combination of two, three, four or more features or elements disclosed in this invention, regardless of whether such features or elements are intentionally combined or otherwise set forth in the description of a particular embodiment of this document. This invention is intended to be read as a whole, so that any individual features or elements of the invention in any of its aspects and embodiments should be considered as intended, namely, as combinable, unless the context of the invention clearly dictates otherwise.

Many modifications and other aspects of the present disclosures set forth herein will be apparent to those skilled in the art to which these disclosures pertain, having benefit of the disclosures set forth in the foregoing description and the accompanying drawings. For example, those skilled in the art will recognize that embodiments not expressly illustrated herein may be practiced within the scope of the present disclosure, including that features described herein for various embodiments may be combined with each other and/or with currently known or future developed technologies, and still remain within the scope of the claims set forth herein.

It is therefore to be understood that the present disclosures are not limited to the specific aspects disclosed and modifications and other aspects are intended to be included within the scope of the appended claims. Although specific terms are used herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Aspects of the present invention are more fully illustrated by the examples herein, which are set forth to illustrate certain aspects of the present invention and are not to be construed as limiting the invention. Unless otherwise indicated, all parts and percentages are by weight.

Claims (39)

1. A smoking article comprising a portion of a mouth end, a control body comprising at least a portion of a heating device, wherein at least a portion of the heating device comprises a resonant transmitter of an induction heater, and an aerosol-generating cartridge in fluid communication with a portion of the mouth end and interacting with the control body, and comprising a shell configured to accommodate an aerosol precursor configured to generate an aerosol upon heating, wherein at least a portion of the shell is permeable such that the aerosol precursor is retained within the shell, while it is possible to release an aerosol formed from the aerosol precursor from the shell through the permeable portion and transmit it to a portion of the mouth end upon heating of the shell or the aerosol precursor therein, and a resonant receiver configured to interact with the resonant transmitter to generate heat for heating the shell or the aerosol precursor therein. 2. The article according to claim 1, wherein the mouthpiece end portion comprises a filter element in fluid communication with the aerosol-producing cartridge. 3. The article of claim 1, wherein the aerosol precursor comprises tobacco beads, tobacco pellets, extruded tobacco, cast sheet tobacco in the form of cut filler, a sheet of reconstituted tobacco material in the form of cut filler, aerosol-forming beads, aluminum oxide beads, a ceramic material, a cast sheet of non-tobacco material in the form of cut filler, a glass mat, a foil sheet, collected paper or gel, or various combinations thereof. 4. The product according to item 1, wherein the shell consists of tobacco, paper or metal or various combinations thereof. 5. The product according to item 1, wherein the shell consists of a multilayer material of paper and foil. 6. The article according to claim 1, in which the shell includes an elongated peripheral wall forming an elongated hollow cylinder having opposite first and second longitudinal ends, and first and second end walls extending respectively laterally across the first and second longitudinal ends of the peripheral wall. 7. The article according to claim 6, wherein one of the first end wall and the second end wall is perforated to release the aerosol from the shell. 8. The product according to item 6, wherein the first end wall and the second end wall are perforated. 9. An article according to any one of paragraphs 6-8, in which one of the first end wall and the second end wall is offset from the corresponding first and second longitudinal end of the peripheral wall. 10. The article according to claim 9, wherein the first end wall includes a first part and a second part, wherein the first part and the second part are not coplanar. 11. The product according to item 10, wherein the first part is offset from the second part along the longitudinal axis of the peripheral wall. 12. An article according to any one of paragraphs 6-11, in which the shell is symmetrical relative to the longitudinal axis of the peripheral wall. 13. An article according to any one of paragraphs. 6-11, in which the shell is symmetrical with respect to a plane dividing the peripheral wall in half between its first and second ends. 14. An article according to any one of paragraphs. 6-13, in which one of the first wall and the second end wall is formed separately from the peripheral wall and is bonded to the peripheral wall by welding, adhesive or friction fit. 15. An article according to any one of paragraphs. 6-13, in which one of the first wall and the second wall includes a folded wrapping material extending laterally across one of the first and second longitudinal ends of the peripheral wall and along the peripheral wall as a layer thereof. 16. An article according to any one of claims 1-15, in which the receiving socket is formed by a control body, is connected to at least said part of the heating device and is designed to receive an end part of the smoking article, wherein the end part is opposite to the part of the mouthpiece end and has an aerosol-generating cartridge connected to it. 17. The article according to claim 1, wherein the resonant receiver is attached to the aerosol generating cartridge. 18. The article according to claim 1, wherein the shell includes a resonant receiver. 19. An article according to any one of claims 1-18, wherein the aerosol-generating cartridge comprises a plurality of aerosol-generating cartridges, and the aerosol precursor in a first one of the plurality of aerosol-generating cartridges has at least one different component from the aerosol precursor in a second one of the plurality of aerosol-generating cartridges. 20. The article according to claim 19, wherein the first one of the plurality of aerosol-generating cartridges and the second one of the plurality of aerosol-generating cartridges are sequentially arranged relative to each other. 21. The product according to any of paragraphs. 1-20, comprising a wrapping material that defines at least a portion of the aerosol-generating cartridge, wherein the wrapping material comprises a multilayer material of sheets of paper and foil, a multilayer material of sheets of paper, foil and paper, a multilayer material of sheets of paper, foil and tobacco, a non-woven graphite sheet, a graphene sheet, a multilayer material of sheets of graphene and foil, a multilayer material of sheets of graphene, foil and paper, a multilayer material of sheets of paper and graphene, graphene ink printed on a paper sheet, graphene ink printed on a foil sheet, carbon nanotubes interacting with a paper sheet or a foil sheet, fullerenes interacting with a paper sheet or a foil sheet, or graphene interacting with a paper sheet or a foil sheet, or various combinations thereof. 22. An aerosol-generating cartridge for use in a smoking article, comprising: an aerosol precursor and a shell configured to receive the aerosol precursor, wherein the aerosol precursor is configured to generate an aerosol upon heating generated by an induction heater comprising a resonant transmitter and a resonant receiver interacting with it, wherein at least part of the shell is permeable such that the aerosol precursor is retained within the shell, while the aerosol formed from the aerosol precursor is capable of being released from the shell through the permeable portion upon heating of the shell or the aerosol precursor therein, wherein the resonant receiver is configured to interact with the resonant transmitter to generate heat for heating the shell or the aerosol precursor therein. 23. The cartridge of claim 22, wherein the aerosol precursor comprises tobacco beads, tobacco pellets, extruded tobacco, cast sheet tobacco in the form of cut filler, a sheet of reconstituted tobacco material in the form of cut filler, aerosol-forming beads, aluminum oxide beads, a ceramic material, a cast sheet of non-tobacco material in the form of cut filler, a glass mat, a foil sheet, collected paper or gel, or various combinations thereof. 24. A cartridge according to claim 22 or 23, wherein the casing consists of tobacco, paper or metal or various combinations thereof. 25. A cartridge according to any one of paragraphs 22-24, wherein the shell consists of a multilayer material of paper and foil. 26. A cartridge according to any one of claims 22 to 25, wherein the shell includes an elongated peripheral wall forming an elongated hollow cylinder having opposite first and second longitudinal ends, and first and second end walls extending laterally across the first and second longitudinal ends of the peripheral wall, respectively. 27. The cartridge of claim 26, wherein one of the first end wall and the second end wall is perforated to release the aerosol from the shell. 28. The cartridge according to claim 26, wherein the first end wall and the second end wall are perforated. 29. A cartridge according to any one of claims 26-28, wherein one of the first end wall and the second end wall is offset from the corresponding first and second longitudinal end of the peripheral wall. 30. The cartridge of claim 29, wherein the first end wall includes a first portion and a second portion, wherein the first portion and the second portion are not coplanar. 31. The cartridge according to claim 30, wherein the first part is offset from the second part along the longitudinal axis of the peripheral wall. 32. A cartridge according to any one of paragraphs 26-31, in which one of the first wall and the second end wall is formed separately from the peripheral wall and is bonded to the peripheral wall by welding, adhesive or friction fit. 33. A cartridge according to any one of claims 26 to 32, wherein one of the first wall and the second wall includes a folded wrapping material extending laterally across one of the first and second longitudinal ends of the peripheral wall and along the peripheral wall as a layer thereof. 34. A cartridge according to any one of paragraphs 26-33, in which the shell is symmetrical relative to the longitudinal axis of the peripheral wall. 35. A cartridge according to any one of claims 26-33, wherein the shell is symmetrical about a plane bisecting the peripheral wall between its first and second ends. 36. A method for producing a smoking article comprising inserting an aerosol precursor into a shell, wherein the aerosol precursor is capable of generating an aerosol upon heating, wherein at least a portion of the shell is permeable such that the aerosol precursor is retained within the shell while an aerosol formed from the aerosol precursor is capable of being released from the shell through the permeable portion upon heating of the shell or the aerosol precursor therein, and at least partially enclosing an aerosol-generating cartridge and a heat-generating element with a first wrapper material to form a subassembly of the smoking article, wherein the heat-generating element is an induction heater comprising a resonant transmitter and a resonant receiver capable of interacting with the resonant transmitter to generate heat for heating the shell or the aerosol precursor therein. 37. The method of claim 36, wherein inserting the aerosol precursor comprises inserting the aerosol precursor into a chamber defined by a peripheral wall of the enclosure, and the method comprises at least partially closing one end of the peripheral wall with an end wall to retain the aerosol precursor within the chamber. 38. The method of claim 37, wherein closing one end of the chamber with an end wall comprises wrapping a wrapping layer around the peripheral wall, the wrapping layer having an end region extending beyond the longitudinal end of the peripheral wall, and folding the end region of the wrapping layer laterally across the longitudinal end of the peripheral wall to form the end wall. 39. The method according to any one of paragraphs 36-38, also comprising sequentially arranging the filter element with the sub-assembly of the smoking article and limiting at least part of the sub-assembly of the smoking article and the filter element with a second wrapping material to form the smoking article.