RU2827803C1 - Electronic smoking product containing heating device implementing source for producing particulate aerosol - Google Patents

Abstract

FIELD: smoking devices.

SUBSTANCE: aerosol delivery devices and systems, such as smoking articles. The smoking article contains: a component housing containing a power source; a reusable mouthpiece having a first end and a longitudinally opposite second end with an internal channel extending between them in the longitudinal direction, the first end being configured to interact with the user's mouth; a housing having a first end and a longitudinally opposite second end, the first end being configured to receive a component housing, and the second end being configured to receive a reusable mouthpiece, the housing comprising an outer wall defining an internal cavity within said housing; and a heating element containing a first section located around the inner surface of the outer wall of the said body, and a second section containing an elongated element passing along the longitudinal axis of the inner cavity of the said body. The first and second sections of the heating element are functionally interacting with the power source and are configured to selectively operate through it to supply heat.

EFFECT: uniform distribution of heat in the source for generating aerosol.

27 cl, 26 dwg

Description

Field of technology

The present invention relates to aerosol delivery devices and systems, such as smoking articles; and in particular to aerosol delivery devices and systems that use electrically generated heat to produce an aerosol (e.g. smoking articles designed to produce tobacco components and other materials in an inhalable form, commonly referred to as electronic cigarettes). Most preferably, the components of such articles are made or obtained from tobacco, or these articles can otherwise be characterized as including tobacco for human consumption and capable of vaporizing tobacco components and/or other tobacco-related materials to form an inhalable aerosol for human consumption.

State of the art

Over the years, many smoking devices have been proposed as improvements to smoking articles or as alternatives to smoking articles that require the combustion of tobacco. Many of these devices have been specifically designed to provide the sensations associated with smoking a cigarette, cigar, or pipe, but without delivering significant amounts of the incomplete combustion and pyrolysis products that result from the combustion of tobacco. To this end, numerous smoking articles, aroma generators, and medicinal inhalers have been proposed that use electrical energy to vaporize or heat a volatile substance or attempt to provide the sensations of smoking a cigarette, cigar, or pipe without burning large amounts of tobacco. For example, various known alternative smoking articles, aerosol delivery devices, and heat generating sources are described in U.S. Patent No. 7,726,320 (Robinson et al.), as well as in U.S. Patent Application Publication Nos. 2013/0255702 (Griffith Jr. et al.) and 2014/0096781 (Sears et al.), which are incorporated herein by reference. In addition, for example, various types of smoking articles, aerosol delivery devices, and electrical heat generating sources with a trademark and commercial information source are presented in U.S. Patent Application No. 14/170,838 (Bless et al.), filed February 3, 2014, which is incorporated herein by reference. Additional types of smoking articles, aerosol delivery devices, and electrical heat-generating sources are listed by trademark and commercial information source in U.S. Patent Application Ser. No. 14/194,233, DePiano et al., filed February 28, 2014, which is also incorporated herein by reference in its entirety.

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

It is preferable to provide a smoking article that utilizes electrically generated heat to provide the sensation of smoking a cigarette, cigar, or pipe, that achieves this without burning tobacco to any significant degree, that achieves this without requiring a combustion heat source, and that achieves this without requiring the delivery of significant amounts of incomplete combustion and pyrolysis products. It is also preferable to provide a smoking article that provides a substantially uniform heat distribution in a particulate aerosol generating source without burning the particulate aerosol generating material to any significant degree.

DISCLOSURE OF THE ESSENCE OF THE INVENTION

The present invention relates to aerosol delivery systems. Such systems are capable of generating an aerosol by supplying heat generated by electrical energy sources and for delivering an aerosol that is intended to be drawn into the mouth of a user. Of particular interest are aerosol delivery systems that convert tobacco components into an aerosol form, such as those provided to smokers in commonly known devices or devices characterized as electronic cigarettes. As used herein, the term "aerosol" includes vapors, gases, aerosols and/or suspended particles in a form or of a type that are suitable for inhalation by a person, regardless of whether they are visible and whether they have a form that can be considered "smoke-like".

The above and other needs are satisfied by aspects of the present invention, which in one aspect include an electronic smoking article and/or an aerosol delivery system. Such a smoking article may comprise a component body containing a power source, and a tubular body having a first end interacting with a mouthpiece, and a second end opposite in the longitudinal direction interacting with the component body. The first or second end may be configured to receive the component body. According to some aspects, the tubular body may comprise an outer wall forming a cylindrical cavity. An aerosol generating element may be configured to be placed inside the cylindrical cavity and may be configured to generate an aerosol upon heating.

According to another aspect of the present invention, a method for producing a smoking article is proposed. This method may include introducing a component body containing a power source into interaction with the first or second end of a tubular body. The tubular body may have a first end interacting with the mouthpiece or the first end, which is located in the longitudinal direction opposite to the second end interacting with the component body. In some aspects, the tubular body may comprise an outer wall forming a cylindrical cavity extending in the lateral direction. In some aspects, the method includes introducing an aerosol generating element into the cylindrical cavity, wherein the element of the aerosol generating element may be designed with the possibility of generating an aerosol upon heating.

In another aspect, an aerosol generating element for a smoking article is proposed, which comprises a hollow cylindrical extrudate of a tobacco-related material to be placed in a heating element extending around the outer surface and inside the inner surface of the hollow cylindrical extrudate, wherein the heating element essentially forms a hollow cylindrical cavity for receiving the hollow cylindrical extrudate, wherein the hollow cylindrical extrudate is configured to respond to the supply of heat supplied by the heating element, with the generation of an aerosol.

According to another aspect, a method for producing an aerosol generating element for a smoking article is proposed. The method may include extruding a tobacco-related material in the form of a hollow cylinder to be placed in a heating element passing around the outer surface and inside the inner surface of the hollow cylindrical extrudate, wherein the heating element essentially forms a hollow cylindrical cavity for receiving the hollow cylindrical extrudate, wherein the hollow cylinder is designed with the possibility of responding to the supply of heat supplied by the heating element, with the generation of an aerosol.

These and other features, aspects and advantages of the present invention will become apparent from reading the following detailed description in conjunction with the accompanying drawings, which are briefly described below.

BRIEF DESCRIPTION OF DRAWINGS

Therefore, on the basis of the general provisions described above, reference will be made in the following to the accompanying drawings, which are not necessarily drawn to scale, and in which:

Fig. 1 shows an illustrative aspect of an electronic smoking article in assembled form, wherein the electronic smoking article has a general appearance similar to the general appearance of an electronic cigarette, which comprises at least a mouthpiece, a component body containing a power source, and a tubular body located therebetween, according to an illustrative aspect of the present invention;

Fig. 2 is a cross-sectional view along line A-A of the electronic smoking article shown in Fig. 1 in assembled form, in which part of the mouthpiece, the component body and the tubular body of the article are excluded to show in detail the internal components;

Fig. 3A shows a typical heating element according to one aspect of the present invention;

Fig. 3B shows a typical heating element according to another aspect of the present invention;

Fig. 4A shows a typical aerosol generating element according to one aspect of the present invention;

Fig. 4B shows a typical aerosol generating element according to another aspect of the present invention;

Fig. 4C shows a typical aerosol generating element according to another aspect of the present invention;

Fig. 4D shows a typical aerosol generating element according to another aspect of the present invention;

Fig. 4E shows a typical aerosol generating element according to another aspect of the present invention;

Fig. 4F shows a typical aerosol generating element according to another aspect of the present invention;

Fig. 4G shows a typical aerosol generating element according to another aspect of the present invention;

Fig. 5 is a block diagram of a method for manufacturing an electronic smoking article according to an illustrative aspect of the present invention;

Fig. 6 is a block diagram of a method for manufacturing an aerosol generating element according to another aspect of the present invention;

Fig. 7 is an illustrative aspect of an assembled electronic smoking article according to one aspect of the present invention;

Fig. 8A is an exploded view of an illustrative aspect of an electronic smoking article in accordance with one aspect of the present invention;

Fig. 8B is an exploded view of an illustrative aspect of an electronic smoking article in accordance with one aspect of the present invention;

Fig. 8C is an exploded view of an illustrative aspect of an electronic smoking article in accordance with one aspect of the present invention;

Fig. 9A is a cross-sectional view taken along line B-B of the electronic smoking article shown in Fig. 8A, in which various elements of the article have been excluded in order to show in detail the internal components according to one aspect of the present invention;

Fig. 9B is a cross-sectional view taken along line B-B of the electronic smoking article shown in Fig. 8B, in which various elements of the article have been excluded in order to show in detail the internal components according to one aspect of the present invention;

Fig. 9C is a cross-sectional view taken along line B-B of the electronic smoking article shown in Fig. 8C, in which various elements of the article have been excluded in order to show in detail the internal components according to one aspect of the present invention;

Fig. 10A shows a typical aerosol generating element according to another aspect of the present invention;

Fig. 10B shows a typical aerosol generating element according to another aspect of the present invention;

Fig. 10C shows a typical aerosol generating element according to another aspect of the present invention;

Fig. 10D shows a typical aerosol generating element according to another aspect of the present invention;

Fig. 10E shows a typical aerosol generating element according to another aspect of the present invention; and

Fig. 11 shows a typical aerosol generating element located within a tubular body of an electronic smoking article according to one aspect of the present invention.

IMPLEMENTATION OF THE INVENTION

The present invention will now be described in more detail with reference to embodiments thereof. These embodiments are described so that the present invention is comprehensive and complete, and fully convey the scope of the present invention to those skilled in the art. It should be noted that the present invention may be implemented in many different forms and should not be considered as limited to the embodiments described in the present application; on the contrary, these embodiments are presented so that the present invention satisfies the requirements of the law. When used in this description and the appended claims, the singular forms include references to the plural forms, unless the context clearly indicates otherwise.

The present document describes articles (and their manufacture) that use electrical energy to heat a material (preferably without burning the material to any significant extent) to generate an aerosol and/or an inhalable substance; such articles are preferably sufficiently compact to be considered portable devices. In some particularly preferred aspects, these articles may be characterized as smoking articles. As used herein, the term "smoking article" means an article and/or device that provides many of the sensations (e.g., the actions of inhaling and exhaling, the nature of the sensation of tastes or aromas, organoleptic effects, physical sensation, actions associated with use, visual cues such as those provided by a visible aerosol, etc.) of smoking a cigarette, cigar, or pipe, without burning to any significant extent any component of the article and/or device. In the context of this document, the term "smoking article" does not necessarily mean that, during operation, the article or device produces smoke, i.e., an aerosol generated from combustion by-products or as a result of pyrolysis of tobacco, but rather that the article or device produces vapors (including vapors in aerosols that can be considered as visible aerosols that can be considered smoke-like) as a result of vaporization or evaporation of certain components, elements and/or the like of this article and/or device. In the most preferred aspects, articles or devices characterized as smoking articles include tobacco and/or components obtained from tobacco.

The articles or devices according to the present invention can also be characterized as vapor-generating articles, articles for delivering an aerosol or articles for delivering a drug. Thus, such articles or devices can be designed to provide one or more substances in a respirable form or in a respirable state. For example, the respirable substances can essentially take a vapor form (i.e., the substance is in a gaseous phase at a temperature below a critical temperature). In an alternative embodiment of the present invention, the respirable substances can take an aerosol form (i.e., a suspension of finely dispersed solid particles or liquid droplets in a gas). For simplicity of description, the term "aerosol" in the context of the present document includes vapors, gases and aerosols in a form or belonging to a type that are suitable for inhalation by a person, regardless of whether they are visible and whether they have a shape that can be considered smoke-like.

During the use of smoking articles according to the present invention, a person, when using a smoking article of a traditional type (for example, a cigarette, cigar or pipe, which is used by lighting with a flame and is used by inhaling tobacco, which gradually burns and/or is burned), performs many physical actions with respect to these articles. For example, a user of a smoking article according to the present invention can hold this article in the same way as a smoking article of a traditional type, draw on one end of said article to inhale an aerosol generated by this article, and release smoke at certain intervals.

Smoking articles according to the present invention typically comprise a number of components housed within an outer shell or body. The overall design of the outer shell or body, as well as the shape or configuration of the outer shell, which may determine the overall size and shape of the smoking article, may vary. Typically, an elongated body resembling a cigarette or cigar in shape may be formed from a single, integral shell; or the elongated body may be formed from two or more separable portions. For example, a smoking article may comprise an elongated shell or body, which may have a substantially tubular shape and, thus, its shape may resemble the shape of a conventional cigarette or cigar. In one aspect, a smoking article may comprise three components of an outer shell, body or portions that are connected and separable. For example, the smoking article may include at one end a power source portion comprising a component body or shell comprising one or more components (e.g. a rechargeable battery and/or various electronic devices, such as a controller, for controlling the operation of the smoking article), a mouthpiece portion comprising a shell containing one or more components (e.g. control components and/or various electronic devices for controlling the operation of the smoking article), and a heat/aerosol generating portion therebetween comprising a shell comprising one or more components (e.g. tobacco solid particles and/or tobacco-related material for generating an aerosol). In another aspect, the smoking article may comprise three outer shell components, bodies or portions that are connected and separable. Additionally or alternatively, the smoking article may comprise an additional component configured to be positioned within one or more of the three outer shell components. For example, the smoking article may include at one end an end cap portion, a mouthpiece portion comprising a shell comprising one or more components (e.g. control components and/or various electronic devices for controlling the operation of the smoking article) and a power source portion therebetween comprising a component housing or shell comprising one or more components (e.g. a rechargeable battery and/or other power source and/or various electronic devices, such as a controller, for controlling the operation of the smoking article. Additionally or alternatively, the end cap portion and/or the power source portion may be configured to receive therein a heat/aerosol generating portion comprising a housing comprising one or more components (e.g. tobacco particulate matter and/or tobacco-related material for generating an aerosol). Furthermore, consideration of commercially available electronic smoking articles, such as the exemplary articles listed in the background section of the present invention, allows for analysis of various smoking article designs and component placements.

Smoking articles according to the present invention most preferably comprise some combination of a power source (i.e. a source of electrical energy), at least one control component (e.g. means for actuating, controlling, regulating and stopping the supply of power for generating heat, such as by controlling the flow of electrical current from the power source to other components of the article), a heater or heat generating component (e.g. an electrical resistive heating element or a component commonly referred to as an "evaporator"), an aerosol generating element (e.g. solid tobacco particles and/or tobacco-related material), and a mouthpiece region, portion or tip for enabling puffing from the smoking article to inhale the aerosol (e.g. a defined air passage in the article through which the generated aerosol can be drawn from it upon puffing). The alignment of the components within the article may vary. In particular aspects, the aerosol generating element may be located between the mouthpiece region and the power source. However, other configurations are also possible. For example, in some aspects, the power source may be located between the mouthpiece region and the aerosol-generating element. Typically, the heating component may be located close enough to the aerosol-generating element so that heat from the heating component can vaporize the aerosol-generating element (as well as one or more flavors, drugs, or the like that may also be provided for delivery to the user) and form an aerosol for delivery to the user. When the heating element heats the aerosol-generating element, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the above terms are intended to be interchangeable, so that reference to release, release, releases, or released includes forming or generating, formation or production, forms or generates, formed or generated. In particular, the inhaled substance is released in the form of a vapor, an aerosol, or a mixture thereof. In addition, when considering commercially available electronic smoking articles, such as the typical articles listed in the section describing the background of the present invention, various components of the smoking articles can be selected.

According to aspects of the present invention, a smoking article includes a battery or other source of electrical energy for supplying an electric current sufficient to provide various functional capabilities of the article, such as resistive heating, powering control systems, powering indicators, etc. The power source may include various aspects. Preferably, the power source is configured to supply a sufficient amount of energy to quickly heat the heating element in order to ensure the formation of an aerosol and to power the article during its use for a desired period of time. The power source is preferably sized to be conveniently placed inside the article for ease of handling; and, in addition, the preferred power source is light enough not to impair the expected smoking sensation.

Examples of suitable power sources include lithium-ion batteries, which are preferably rechargeable (e.g., a rechargeable lithium/manganese dioxide battery). In particular, lithium polymer batteries can be used, since such batteries can provide increased safety. In addition, other types of batteries can be used, such as N50-AAA CADNICA nickel-cadmium cells. Several other examples of batteries that can be used according to the present invention are described in U.S. Patent Application Publication No. 2010/0028766 (Peckerar et al.), the disclosure of which is incorporated herein by reference in its entirety. In certain aspects of the present invention, thin-film batteries can be used. Any of these batteries or combinations thereof can be used in the power source, but rechargeable batteries are preferred due to cost and disposal considerations associated with disposable batteries. In aspects in which disposable batteries are provided, the smoking article may provide access for removing and replacing the battery. Alternatively, in aspects in which rechargeable batteries are used, the smoking article may comprise charging contacts for interacting with corresponding contacts in a conventional charger that is connected to a standard 120-volt AC wall outlet or other sources, such as a vehicle electrical system or a separate portable power source having a USB connection. The means for recharging the battery may be installed in a portable charging case, which may include, for example, a relatively large battery pack that can provide multiple recharging cycles for relatively small batteries present in the smoking article. In addition, the article may comprise components for providing a contactless inductive charging system so that the article can be charged without a physical connection to an external power source. Thus, the product may include components to facilitate the transfer of energy from the electromagnetic field to a rechargeable battery located within the product.

In some aspects, the power source may also comprise one or more capacitors. For example, the power source may include a combination of any number of batteries and/or capacitors. In some aspects, the power source may include at least one battery and at least one capacitor. The capacitors are capable of discharging faster than batteries and may be charged between puffs, which allows the battery to be discharged into the capacitor at a slower rate than when directly used to power the heating element. For example, a high-capacity capacitor, i.e., an electric double-layer capacitor (EDLC), may be used separately from the battery or in combination with it. When used separately, the high-capacity capacitor may be charged before each use of the article. Thus, the present invention may also include a charging component that may be connected to the smoking article during a period of non-use to recharge the high-capacity capacitor.

The smoking article may further include a plurality of power management programs, hardware and/or other electronic control components. For example, such software, hardware and/or electronic control means may provide such functions as battery charging, battery charge and discharge status detection, energy saving operations, prevention of accidental or excessive battery discharge and/or the like.

"Controller", "control component" and/or "control unit" according to the present invention may include a plurality of elements suitable for use in the present smoking article. Furthermore, the smoking article according to the present invention may include one, two or even more control units, which may be combined into a single element or which may be located in different places of the smoking article, and individual control units may be used to implement different aspects of control. For example, the smoking article may include a control unit, which is made integrally or otherwise combined with a battery to control the consumption of electric power of the battery. The smoking article may further include a control unit, which controls other functions of the article, for example, regulation of the heating component to ensure a certain heating temperature of the aerosol generating element. Alternatively, one controller may be provided, which performs a plurality of control functions or all control functions of the article. Similarly, a sensor (for example, a smoke emission and/or puff sensor) used in the article may include a control unit, which controls the activation of power consumption from the power source in response to a control signal. The smoking article may further comprise a control unit that controls other functions of the article. Alternatively, one controller may be installed in the sensor or otherwise associated with the sensor, and this controller is intended to perform a plurality of control functions or all control functions of the article. Thus, in the present smoking article, various combinations of controllers may be combined to provide the required level of control of all functional capabilities of the article.

The smoking article may also comprise one or more controller units applicable for controlling the flow of electric energy from the power source to other components of the article, such as the heating element. In particular, the article may comprise a control unit that includes the supply of electric current from the power source to the heating element. According to some aspects of the present invention, the smoking article may comprise a push-button switch that may be connected to a control circuit for manually controlling the switching on of the electric current supply, wherein the consumer may use this push-button switch to switch on the article and/or to switch on the supply of electric current to the heating element. A plurality of buttons may be provided for manually controlling the switching on and off of the article, as well as for switching on the heating of the heating element, for example, a resistive heating element, for generating an aerosol. One or more push-button switches may be mounted substantially flush with the outer surface of the smoking article.

Instead of (or in addition to) a push-button switch, the smoking article may include one or more control units that are responsive to a user drawing on the article (i.e., a smoke-activated heating). For example, the article may include a switch that is responsive to either pressure changes or airflow changes when the user draws on the article (i.e., a smoke-activated switch). Other suitable mechanisms for turning on/off the current supply may include a temperature-activated on/off switch or a pressure-activated switch at the mouthpiece. An exemplary mechanism that may provide such smoke-activated capability includes a silicon sensor model 163PC01D36 manufactured by the MicroSwitch division of Honeywell, Inc., Freeport, Ill. With such a sensor, the heating element can be rapidly activated by a pressure change when the user draws on the article. In addition, flow measurement devices, such as those using hot-wire anemometry principles, may be used to initiate current flow to the heating element sufficiently quickly upon detection of a change in air flow. A differential pressure switch, such as the Model MPL-502-V, Range A, manufactured by Micro Pneumatic Logic, Inc., Fort Lauderdale, Florida, may be used as an additional smoke-activated switch. Another suitable smoke-activated mechanism is a sensitive pressure sensor (e.g., equipped with an amplifier or gain stage) which, in turn, is connected to a comparator to determine whether a predetermined threshold pressure has been reached. Another suitable smoke-activated mechanism is an airflow-deflected vane, the motion of the vane being detected by a motion detection means. Another suitable activation mechanism is a piezoelectric switch. In addition, a suitably connected Honeywell MicroSwitch microbridge air flow sensor, Part No. AWM 2100V, manufactured by the MicroSwitch Division of Honeywell, Inc., Freeport, Ill., may be used. Other examples of electrical switches that operate in response to a control action that may be used in the heating circuit of the present invention are described in U.S. Patent No. 4,735,217 (Gerth et al.), the disclosure of which is incorporated herein by reference in its entirety. The possibility of using other suitable differential switches, analog pressure sensors, flow sensors, etc. in the present invention will be apparent to those skilled in the art. A pressure measuring tube or other passage may be used that provides a fluid connection between the switch activated by the release of smoke and the air flow passage within the smoking article, so that a change in pressure during a puff is easily detected by the switch. In addition, current control circuits and other control units, including microcontrollers, that may be suitable for use in the present smoking article are described in U.S. Patents Nos. 4,922,901, 4,947,874, and 4,947,875 (Brooks et al.), U.S. Patent No. 5,372,148 (McCafferty et al.), U.S. Patent No. 6,040,560 (Fleischhauer et al.), and U.S. Patent No. 7,040,314 (Nguyen et al.), which are incorporated herein by reference in their entirety.

In particular, the device may include components for measuring capacitance in various ways to provide various types of "power on" and/or "power off" for one or more components of the device. Measuring capacitance may involve the use of any sensor that operates based on capacitive coupling technology, including, among others, sensors that detect and/or measure proximity, position or displacement, humidity, fluid level, pressure or acceleration. Measuring capacitance may be based on the use of electronic components that detect surface capacitance, projected capacitance, mutual capacitance or self-capacitance. Capacitive sensors are typically capable of detecting anything that is conductive or contains a dielectric other than air. Capacitive sensors, for example, allow mechanical buttons (i.e., the pushbutton switch mentioned above) to be replaced with an alternative capacitive device. Thus, one particular application of measuring capacitance according to the present invention is a touch capacitive sensor. For example, the smoking article may comprise a touch-sensitive part (i.e., a touch panel) that allows the user to enter various commands. In essence, the touch panel may provide for the activation of the heating element in the same manner as the push-button switch described above. In other aspects, the capacitance measurement may be applied near the mouthpiece of the smoking article in such a way that the presence and/or pressure of the lips on the smoking article or a puff using the article may be a signal to the device about the need to supply power to the heating element. In addition to the touch capacitive sensors according to the present invention, capacitive motion sensors, liquid capacitive sensors and accelerometers may be used to initiate various responses from the smoking article. In addition, photoelectric sensors may also be included in the smoking article according to the present invention.

The sensors used in the present smoking articles can directly signal the need to supply power to the heating element to heat the aerosol generating element and form an aerosol for inhalation by the user. The sensors can also perform additional functions. For example, a "wake-up" sensor (return to the operating mode from the standby mode) can be used. In addition, according to the present invention, other sensing methods can be used that provide similar functionality.

When the consumer draws on the mouthpiece of the smoking article, the actuation means may initiate an unlimited or continuous flow of electric current through the heating element to rapidly generate heat. Due to the rapid heating, it may be advisable to include current control components to (i) regulate the current flowing through the heating element to control the heating of the resistive element and the temperature achieved, and (ii) prevent overheating and decomposition of the aerosol generating elements.

The current control circuit may in particular be synchronized. In particular, such a circuit includes means for ensuring a continuous current flow through the heating element for an initial period of time during a puff and synchronizing means for subsequently regulating the current flow until the puff is completed. For example, the subsequent regulation may include rapidly switching on and off the current flow (for example, in the order of approximately 1-50 milliseconds) to maintain the desired temperature range on the heating element. In addition, the regulation may include only ensuring a continuous current flow until the desired temperature is reached, and then completely turning off the current. The heating element may be reactivated by a user performing another puff using the article (or by manually pressing a push-button switch, depending on the particular applied shutdown aspect used to activate the heater). Alternatively, the subsequent regulation may include modulating the current flowing through the heating element to maintain the desired temperature range on the heating element. In some aspects, to release the desired amount of inhalable substance, the heating element may be connected to a power source for about 0.2 seconds to about 5.0 seconds, about 0.3 seconds to about 4.5 seconds, about 0.5 seconds to about 4.0 seconds, about 0.5 seconds to about 3.5 seconds, or about 0.6 seconds to about 3.0 seconds. One typical synchronized current regulation circuit may include a transistor, a timer, a comparator, and a capacitor. Suitable transistors, timers, comparators, and capacitors are commercially available and will be obvious to one skilled in the art. Typical timers include, for example, the C-1555C manufactured by NEC Electronics and the ICM7555 manufactured by General Electric Intersil, Inc., as well as various so-called "555 timers" of other sizes and configurations. A typical comparator, the LM311, is manufactured by National Semiconductor. In addition, a description of such synchronized current control circuits and other control units that may be suitable for use in the present smoking article is given in U.S. Patents Nos. 4,922,901, 4,947,874, and 4,947,875 (Brooks et al.), which are incorporated herein by reference in their entirety.

The control units may in particular be configured to precisely control the amount of heat supplied to the heating element. In some aspects, the current control component may be operable to stop supplying current to the heating element once a certain temperature is reached. Such certain temperature may be in a range in which the temperature is high enough to ensure vaporization of the aerosol generating element and any additional inhalable substances and to provide an amount of aerosol equivalent to a typical puff of a conventional cigarette, as discussed herein for other cases. Although the heat required to vaporize the aerosol generating element in a sufficient volume to provide the required volume thereof for one puff may vary, it may be particularly appropriate to heat the heating element to a temperature of about 120°C or higher, about 130°C or higher, about 140 ºC or higher, or about 160 ºC. In some aspects, the heating temperature may be about 180°C or higher, about 200°C or higher, about 300ºC or higher, or about 350ºC or higher to vaporize a suitable amount of the aerosol generating element. In other aspects, the specific aerosol formation temperature may be from about 120°C to about 350°C, from about 140°C to about 300°C, or from about 150°C to about 250°C. The heating temperature and time may be controlled by one or more components contained in the smoking article. For example, the temperature may be adjusted by one or more components that may respond to user commands to provide a specific desired temperature, such as a heating temperature of the aerosol generating element, a standby temperature, and/or the like. For example, the temperature can be controlled by one or more components that are responsive to user commands, providing for selection of a desired aerosol-generating heating temperature, based at least on the composition of the aerosol-generating element. Similarly, a current control component is capable of cyclically turning on and off the supply of current to the resistive heating element upon reaching a certain temperature to maintain this temperature for a certain period of time.

In addition, the current control component is capable of cyclically turning on and off the current supply to the heating element to maintain a first temperature that is lower than the aerosol formation temperature, and then can increase the flowing current in response to the current supply control component to achieve a second temperature that is higher than the first temperature and that is the aerosol formation temperature. Such control can increase the reaction rate of the article with respect to aerosol formation such that aerosol formation begins almost instantly after the consumer starts smoking. According to some aspects, the first temperature (which can be characterized as the standby temperature) can be only slightly lower than the aerosol formation temperature defined above. In particular, the standby temperature can be from about 50°C to about 150°C, from about 70°C to about 140°C, from about 80°C to about 120°C, or from about 90°C to about 110°C.

In addition to the above-mentioned control elements, the smoking article may also comprise one or more indicators or indicators. Such indicators or indicators may be lamps (e.g., light-emitting diodes), which may provide indication of multiple aspects of the use of the article according to the present invention. In addition, LED indicators may be located at the far end of the smoking article to simulate color changes observed when the user lights and draws on a conventional cigarette. The present invention also covers other options for the functioning of the indication. For example, visual indicators of operation may also include a change in color or intensity of light, indicating the progress of the smoking process. The present invention also covers tactile and sound indicators of operation. In addition, combinations of such indicators of operation may also be used in a separate smoking article. According to another aspect, the smoking article may include one or more indicators or pointers, such as, for example, a display, configured to provide information about the operation of the smoking article, such as, for example, the amount of energy remaining in the power source, the progress of the smoking process, an indication corresponding to the activation of the heating element, and/or the like.

The smoking article according to the present invention may further comprise a heating element that heats the aerosol-generating element in order to produce an aerosol for inhalation by the user. In various aspects, the heating element may be made of a material that provides resistive heating when an electric current is applied to it. Preferably, the heating element has an electrical resistance, due to which the resistive heating element is suitable for providing a sufficient amount of heat when an electric current flows through it. The interaction of the heating element with the aerosol-generating element may be achieved, for example, by using thermal conductivity, thermal radiation and/or thermal convection.

Electrically conductive materials useful as resistive heating elements may be materials that have a low mass, low density and moderate resistivity, and that are thermally stable at the temperatures encountered during use. Suitable heating elements heat up and cool down quickly and thus provide efficient use of energy. Rapid heating of the element may help to provide for almost instantaneous evaporation of the aerosol-generating element in its immediate vicinity. Rapid cooling (i.e. to a temperature below the evaporation temperature of the aerosol-generating element/component/composition/material) prevents strong evaporation (and thus waste formation) of the aerosol-generating element during periods when aerosol formation is not required. Such heating elements also provide relatively precise control over the range of temperatures to which the aerosol-generating element is exposed, in particular when using synchronized current control. Suitable conductive materials preferably do not chemically react with the heated materials (e.g., aerosol generating elements and/or other materials of the inhalable substance), so that they cannot negatively affect the taste or content of the generated aerosol or vapor. Typical materials that can be used as conductive material include, among others, carbon, graphite, carbon-graphite composites, metals, metallic and non-metallic carbides, nitrides, silicides, intermetallic compounds, metal-ceramic materials, metal alloys and metal foil. In particular, refractory materials can be used. Many different materials can be mixed to achieve the desired properties: specific resistance, mass and thermal conductivity. In particular aspects, usable metals include, for example, nickel, chromium, nickel-chromium alloys (e.g., nichrome) and steel. Materials that can be used to provide resistive heating are described in U.S. Patent No. 5,060,671 (Counts et al.); U.S. Patent No. 5,093,894 (Deevi et al.); 5,224,498 (Deevi et al.); U.S. Patent No. 5,228,460 (Sprinkel Jr. et al.); U.S. Patent No. 5,322,075 (Deevi et al.); U.S. Patent No. 5,353,813 (Deevi et al.); U.S. Patent No. 5,468,936 (Deevi et al.); U.S. Patent No. 5,498,850 (Das); U.S. Patent No. 5,659,656 (Das); U.S. Patent No. 5,498,855 (Deevi et al.); U.S. Patent No. 5,530,225 (Hajaligol); U.S. Patent No. 5,665,262 (Hajaligol); U.S. Patent No. 5,573,692 (Das et al.); and U.S. Patent No. 5,591,368 (Fleischhauer et al.), the disclosures of which are incorporated herein by reference in their entirety.

The heating element may be in various forms, such as foil, sponge, disks, coils, fibers, wire, films, threads, strips, tapes or cylinders. In some aspects, the resistive heating element according to the present invention may be a conductive substrate, such as described in US Patent Application Publication No. 2013/0255702 (Griffith et al.), the disclosure of which is incorporated herein by reference in its entirety.

Preferably, the resistive heating element may be formed in a shape that allows the heating element to be mounted in direct contact with the aerosol generating element or in close proximity to it (i.e., to supply heat to the aerosol generating element by, for example, conduction, radiation or convection). In other aspects, the resistive heating element may be formed in such a shape that the aerosol generating element may be located near the resistive heating element for substantially uniform heat distribution for aerosolization of the aerosol generating element.

In some aspects, a smoking article according to the present invention may include an aerosol generating element that may comprise tobacco, a tobacco component, or a tobacco derived material (i.e., a material that is naturally present in tobacco and that may be directly isolated from tobacco or produced synthetically). In some aspects, the aerosol generating element may comprise a blend of flavored and aromatic tobaccos in the form of cut filler. In another aspect, the aerosol generating element may comprise a reconstituted tobacco material, such as that described in U.S. Patent No. 4,807,809 (Pryor et al.); U.S. Patent No. 4,889,143 (Pryor et al.); and U.S. Patent No. 5,025,814 (Raker), the disclosures of which are incorporated herein by reference in their entirety. In addition, the reconstituted tobacco material may include reconstituted tobacco packaging paper described for the type of cigarettes described in R. J. Reynolds Tobacco Company's monograph "Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco" (1988), the contents of which are incorporated herein by reference in their entirety. For example, the reconstituted tobacco material may include a sheet material containing tobacco and/or tobacco-related materials. In some aspects, the aerosol generating element may be formed from a wound roll of reconstituted tobacco material. In another aspect, the aerosol generating element may be formed from shreds, strips, and/or related reconstituted tobacco material.

According to another aspect, a smoking article according to the present invention may include an aerosol generating element, which may include a porous inert material, such as, for example, a ceramic material. In another aspect, the aerosol generating element may include a porous inert material that is substantially chemically and/or physically non-reactive with a tobacco-related material, such as, for example, an extract obtained from tobacco.

Useful tobacco may include (or be derived from) such tobaccos as flue-cured, burley, oriental, Maryland, black, fire-cured, and shag, as well as other rare or specialty tobaccos, or blends thereof. Various representative tobacco types, processed tobacco types, and tobacco blend types are described in U.S. Patent No. 4,836,224 (Lawson et al.); U.S. Patent No. 4,924,888 (Perfetti et al.); U.S. Patent No. 5,056,537 (Brown et al.); U.S. Patent No. 5,159,942 (Brinkley et al.); U.S. Patent No. 5,220,930 (Gentry); U.S. Patent No. 5,360,023 (Blakley et al.); U.S. Patent No. 6,701,936 (Shafer et al.); U.S. Patent No. 6,730,832 (Dominguez et al.); U.S. Patent No. 7,011,096 (Li et al.); U.S. Patent No. 7,017,585 (Li et al.); U.S. Patent No. 7,025,066 (Lawson et al.); U.S. Published Patent Application No. 2004/0255965 (Perfetti et al.); PCT Published Patent Application No. WO 02/37990 (Bereman; also Bombick et al.), Fund. Appl. Toxicol ., 39, p. 11-17 (1997); the disclosure of which is incorporated herein by reference in its entirety.

According to another aspect of the present invention, the aerosol generating element may include tobacco, a tobacco component, and/or a tobacco-derived material that can be cleaned, processed, recovered, and/or treated to include an aerosol generating material (e.g., humectants such as, for example, propylene glycol, glycerin, and/or the like) and/or at least one flavoring agent, as well as a flame retardant (e.g., diammonium phosphate and/or another salt) configured to prevent ignition, pyrolysis, combustion, and/or overheating of the aerosol generating element by the heating element. Various methods of incorporating tobacco into smoking articles, and in particular smoking articles that are designed to specifically not burn substantially all of the tobacco in the smoking articles, are described in U.S. Patent No. 4,947,874 (Brooks et al.); U.S. Patent No. 7,647,932 (Cantrell et al.); U.S. Patent No. 8,079,371 (Robinson et al.); U.S. Patent No. 7,290,549 (Banerjee et al.); and U.S. Published Patent Application No. 2007/0215167 (Crooks et al.); the disclosures of which are incorporated herein by reference in their entirety.

According to one aspect of the present invention, fire-resistant materials and additives that can be included in the aerosol-generating element can include organophosphorus compounds, borax, aluminum hydroxide, graphite, potassium tripolyphosphate, dipentaerythritol, pentaerythritol and polyols. Other substances can be used, such as nitrogen salts of phosphonic acid, monoammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ethanolammonium borate, ammonium sulfamate, halogenated organic compounds, thiourea and antimony oxides, but they are not preferred substances. In each aspect of the non-flammable, fire-resistant, and/or burn-resistant materials used in the aerosol generating element and/or other components (whether individually or in combination with each other and/or with other materials), the required properties are most preferably achieved without undesirable outgassing or melting.

According to another aspect of the present invention, the aerosol generating element may also include tobacco additives that are commonly used in the manufacture of tobacco products. These additives may include materials of the types used to enhance the flavor and aroma of tobaccos in the manufacture of cigars, cigarettes, pipes, and the like. For example, these additives may include various cigarette casings and/or topcoat components. See, for example, U.S. Patent No. 3,419,015 (Wochnowski); U.S. Patent No. 4,054,145 (Berndt et al.); U.S. Patent No. 4,887,619 (Burcham, Jr. et al.); U.S. Patent No. 5,022,416 (Watson); U.S. Patent No. 5,103,842 (Strang et al.); and U.S. Patent No. 5,711,320 (Martin); the disclosures of which are incorporated herein by reference in their entirety. Preferred shell materials include water, sugars and syrups (e.g., sucrose, glucose, and high fructose corn syrup), humectants (e.g., glycerin or propylene glycol), and flavoring agents (e.g., cocoa and licorice). These added components also include topcoat materials (e.g., flavoring materials such as menthol). See, for example, U.S. Patent No. 4,449,541 (Mays et al.), the disclosure of which is incorporated herein by reference in its entirety. In addition, the materials described in U.S. Patent No. 4,830,028 (Lawson et al.) and U.S. Patent 8,186,360 (Marshall et al.), the disclosure of which is incorporated herein by reference in its entirety, may be added.

For example, in some aspects, the aerosol generating element may comprise one or more different components, such as an aerosol generating material such as, for example, a polyhydric alcohol (e.g., glycerin, propylene glycol, or a mixture thereof). Representative examples of other aerosol generating materials are provided in U.S. Patent No. 4,793,365 (Sensabaugh, Jr., et al.); U.S. Patent No. 5,101,839 (Jakob, et al.); PCT WO 98/57556 (Biggs, et al.); and R. J. Reynolds Tobacco Company, "Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco" (1988), the disclosures of which are incorporated herein by reference. In some aspects, using an aerosol generating element, a visible aerosol can be generated when sufficiently heated (and, if necessary, cooled by air) and the aerosol generating element can generate an aerosol that can be considered "smoke-like". In other aspects, the aerosol generating element can generate an aerosol that may be substantially invisible, but can be recognized as being present by other characteristics, such as aroma or texture. Thus, the nature of the resulting aerosol can vary depending on the specific components of the aerosol generating element. The aerosol generating element can be chemically simple compared to the chemical nature of smoke generated by burning tobacco.

A variety of flavoring agents or materials may be used that alter the sensory or organoleptic character or nature of the primary aerosol of the smoking article. Such flavoring agents may be derived from sources other than tobacco and may be natural or artificial in nature. Of particular interest are flavoring agents that coat or are introduced into the aerosol-generating element and/or the aerosol-generating areas of the smoking article. Again, such agents may be supplied directly into the heating cavity near the resistive heating element or they may be provided on a substrate. Examples of flavoring agents include vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, and packaged flavoring agents and additives of a specific type and character that are traditionally used to flavor cigarette, cigar, and pipe tobaccos. Syrups, such as high fructose corn syrup, may also be used. Flavoring agents may also include substances with acidic or basic characteristics (e.g., organic acids such as levulinic acid, succinic acid, and pyruvic acid). If desired, the flavoring agents may be combined with the aerosol generating material. Exemplary useful plant-derived compositions are described in U.S. Patent Application Ser. No. 12/971,746 (Dube et al.) and U.S. Patent Application Ser. No. 13/015,744 (Dube et al.), the disclosures of which are incorporated herein by reference in their entirety. The selection of such additional components may vary depending on such factors as the sensory characteristics desired for the present article, and the present invention encompasses any such additional components that may be readily apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See: Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972), and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972), the disclosures of which are incorporated herein by reference in their entirety.

Any of the materials, such as flavorings, coatings, etc., that can be used in combination with the tobacco material to change its sensory properties, including organoleptic properties, such as those already described herein, can be combined with the aerosol generating element. Organic acids, in particular, can be included in the aerosol generating element to change the aroma, sensation, or organoleptic properties of drugs, such as nicotine, which can be combined with the aerosol generating element. For example, organic acids such as levulinic acid, lactic acid, and pyruvic acid can be included in the aerosol generating element with nicotine in amounts up to equimolar (based on the total organic acid content) to nicotine. Any combination of organic acids can be used. For example, the aerosol generating element may comprise from about 0.1 to about 0.5 moles of levulinic acid per mole of nicotine, from about 0.1 to about 0.5 moles of pyruvic acid per mole of nicotine, from about 0.1 to about 0.5 moles of lactic acid per mole of nicotine, or combinations thereof up to a concentration at which the total amount of organic acid present is equimolar to the total amount of nicotine present in the aerosol generating element. Various other examples of organic acids used to form an aerosol generating element are described in U.S. Patent Application Ser. No. 14/721,283 (Dull et al.), filed May 26, 2015, which is incorporated herein by reference in its entirety.

In another aspect of the present invention, the aerosol generating element may be in the form of an extruded structure and/or a support that may include or may essentially consist of tobacco, a tobacco-related material, glycerin, water, and/or a binder, although some formulations may not contain a binder. The binder may be any binder typically used for tobacco compositions, including, for example, carboxymethyl cellulose (CMC), a gum (e.g., guar gum), xanthan, pullulan, and/or alginate. According to some aspects, the binder included in the aerosol generating element may be designed to substantially maintain the structural shape and/or integrity of the aerosol generating element. Various typical binders, binder properties, bonding methods, and amounts of binders are disclosed in U.S. Patent No. 4,924,887 (Raker et al.), which is incorporated herein by reference in its entirety.

In another aspect, the aerosol generating element may include a plurality of microcapsules, beads, granules and/or the like containing a tobacco-related material. For example, a typical microcapsule may have a generally spherical shape and may have an outer layer or shell that contains a region for concentrating liquid of an extract obtained from tobacco and/or the like. In some aspects, the aerosol generating element may include a plurality of microcapsules having a substantially hollow cylindrical shape. In one aspect, the aerosol generating element may include a binder material substantially designed to maintain the structural shape and/or integrity of the plurality of microcapsules having a substantially hollow cylindrical shape.

In some aspects, the aerosol generating element may be an extruded material, as described in U.S. Patent Application Publication No. 2012/0042885 (Stone et al.), which is incorporated herein by reference in its entirety. In another aspect, the aerosol generating element may include an extruded structure and/or substrate formed from marumarized and/or non-marumarized tobacco. Marumarized tobacco is known, for example, from U.S. Patent No. 5,105,831 (Banerjee et al.), which is incorporated herein by reference in its entirety. Marumarized tobacco may include from about 20 to about 50 percent (by weight) of a tobacco blend in powder form with glycerin (from about 20 to about 30 weight percent), calcium carbonate (typically from about 10 to about 60 weight percent, often from about 40 to about 60 weight percent), together with binders and/or flavoring agents described herein.

The aerosol generating element may have one of a variety of different shapes, depending on the amount of materials used therein, which may vary. For example, a suitable aerosol generating element may comprise up to about 98 wt. %, up to about 95 wt. %, or up to about 90 wt. % tobacco and/or tobacco material. A suitable aerosol generating element may also comprise up to about 25 wt. %, about 20 wt. %, or about 15 wt. % water, in particular from about 2 wt. % to about 25 wt. %, from about 5 wt. % to about 20 wt. %, or from about 7 wt. % to about 15 wt. % water. Flavors and the like (which may include medicaments such as nicotine) may comprise up to about 10 wt. %, up to about 8 wt. %, or up to about 5 wt. % of the aerosol generating element.

In addition, or alternatively, the aerosol generating element may be formed as an extruded structure and/or a substrate that may include or may essentially consist of tobacco, glycerin, water and/or a binder and may further be configured to substantially maintain its structure during the aerosol generation process. In other words, the aerosol generating element may be configured to substantially maintain its shape (i.e., the aerosol generating element does not deform continuously under the action of an applied shear stress) during the aerosol generation process. Although the aerosol generating element may contain liquids and/or may have some moisture content, the aerosol generating element remains substantially solid and substantially maintains structural integrity during the aerosol generation process. Illustrative tobacco and/or tobacco-related materials suitable as a substantially solid aerosol-generating element are described in U.S. Patent Application Ser. No. 14/098,137, filed December 5, 2013 (Ademe et al.); U.S. Patent Application Ser. No. 14/282,768, filed May 20, 2014 (Sears et al.); U.S. Pat. No. 6,164,287 (White); and U.S. Pat. No. 5,060,676 (Hearn et al.), which are respectively incorporated herein by reference in their entireties.

The amount of aerosol generating element used in the smoking article is provided so that the article has acceptable sensory and organoleptic properties, as well as the required performance characteristics. For example, it is most preferable that a sufficient amount of aerosol generating material, such as, for example, glycerin and/or propylene glycol, is used in the aerosol generating element to ensure the generation of a visible primary aerosol, which in many respects resembles the appearance of tobacco smoke. Typically, the amount of aerosol generating material contained in an aerosol generating element of a smoking article is approximately 1.5 g or less, approximately 1 g or less, or approximately 0.5 g or less.

The amount of the aerosol generating element may depend on factors such as the preferred number of puffs per cartridge used with the smoking article. It is desirable that the aerosol generating element not contribute to any significant degree an unpleasant off-flavor, a filmy mouthfeel, or an overall sensory experience that is significantly different from the traditional cigarette type experience that accompanies the mainstream smoke from burning cut tobacco filler. The selection of the specific aerosol generating material, the amount of its components, and the types of tobacco material used may be varied to control the overall chemical composition of the aerosol produced by the aerosol generating element of the smoking article.

In other aspects, the heating can be characterized depending on the amount of aerosol generated. In particular, the article can be configured to provide the amount of heat necessary to generate a certain volume of aerosol (e.g., from about 0.5 ml to about 100 ml, or any other volume suitable for a smoking article, such as those specified elsewhere herein). In certain cases, the amount of heat generated can be measured in relation to a two-second puff providing about 35 ml of aerosol at a heater temperature of about 290 °C. In some aspects, the article can preferably provide from about 1 to about 50 joules of heat per second (J/s), from about 2 J/s to about 40 J/s, from about 3 J/s to about 35 J/s, or about 5 J/s to about 30 J/s.

The heating element is preferably electrically connected to the power source of the smoking article in such a way that electrical energy can be supplied to the heating element to generate heat and then to aerosolize the aerosol generating element and any other inhalable substance provided by the smoking article. Such an electrical connection can be permanent (e.g. with a hard wire connection) or can be detachable (e.g. in which the resistive heating element is installed in a housing or section that can be connected to the power source and disconnected from the power source).

Although a variety of materials for use in the smoking article of the present invention have been described above, such as heaters, batteries, capacitors, switching components, aerosol generating elements, aerosol generating materials, and/or the like, the present invention should not be construed as limited to these illustrative aspects alone. Rather, one skilled in the art, having learned of the present invention, will recognize similar components in the art that may be interchangeable with any particular component of the present invention. For example, U.S. Patent No. 5,261,424 (Sprinkel, Jr.) describes piezoelectric sensors that may be coupled to a mouthpiece of the device to detect user lip activity associated with a puff and subsequently initiate heating; U.S. Patent No. 5,372,148 (McCafferty et al.) describes a puff sensor for controlling the supply of energy to a heat load array when pressure drops across a mouthpiece; U.S. Patent No. 5,967,148 (Harris et al.) describes receivers in a smoking device that include a recognizer that detects infrared transmittance non-uniformity for an introduced component, and a controller that performs a procedure for determining when the component is introduced into the receiver; U.S. Patent No. 6,040,560 (Fleischhauer et al.) describes a detectable executable power on/off cycle with a plurality of differential phases; U.S. Patent No. 5,934,289 (Watkins et al.) describes photonic optoelectronic components; U.S. Patent No. 5,954,979 (Counts et al.) describes means for varying the draw resistance through a smoking device; U.S. Patent No. 6,803,545 (Blake et al.) describes specific battery configurations for use in smoking devices; U.S. Patent No. 7,293,565 (Griffen et al.) describes various charging systems for use with smoking devices; U.S. Patent Application Publication No. 2009/0320863 (Fernando et al.) describes a computer interface for smoking devices that facilitates charging and allows the device to be controlled by a computer; and U.S. Patent Application Publication No. 2010/0163063 (Fernando et al.) describes identification systems for smoking devices; all of the foregoing inventions are incorporated herein by reference in their entireties. Other examples of components related to electronic aerosol delivery articles and descriptions of materials or components that may be used in the present article include U.S. Patent No. 4,735,217 (Gerth et al.); U.S. Patent No. 5,249,586 (Morgan et al.); U.S. Patent No. 5,666,977 (Higgins et al.); U.S. Patent No. 6,053,176 (Adams et al.); U.S. Patent No. 6,164,287 (White); U.S. Patent No. 6,192,218 (Voges); U.S. Patent No. 6,810,883 (Felter et al.); U.S. Patent No. 6,854,461 (Nichols); U.S. Patent No. 7,832,410 (Hon); U.S. Patent No. 7,513,253 (Kobayashi); U.S. Patent No. 7,896,006 (Hamano); U.S. Patent No. 6,772,756 (Shayan); U.S. Patent Nos. 8,156,944, 8,375,957 (Hon); U.S. Published Patent Application Nos. 2006/0196518 and 2009/0188490 (Hon); U.S. Patent No. 8,794,231 (Thorens et al.); U.S. Patent Nos. 8,915,254 and 8,925,555 (Monsees et al.); U.S. Patent No. 8,851,083 and U.S. Published Patent Application No. 2010/0024834 (Oglesby et al.); U.S. Published Patent Application No. 2010/0307518 (Wang); and WO 2010/091593 (Hon). The various materials described in the above documents can be used in the present devices in various aspects and all of the above inventions are incorporated herein by reference in their entirety.

Although the article according to the present invention may include various aspects, as discussed in more detail below, the use of the smoking article by the consumer will be the same in scope. In particular, the smoking article may be made in the form of a single unit or in the form of a plurality of bodies containing various components that the consumer combines for use and then removes. In one aspect, the smoking article according to the present invention may comprise a first unit that is configured to be brought into interaction with and removed from interaction with a second unit, and a third unit that is configured to be brought into interaction with and removed from interaction with the second unit, wherein the second unit comprises a resistive heating element, and the third unit comprises a source of electrical energy. According to another aspect, the smoking article may comprise a first unit that is configured to be brought into interaction with and removed from interaction with the third unit, and a second unit that is configured to be brought into interaction with and removed from interaction with the third unit, wherein the second unit comprises a resistive heating element, and the third unit comprises a source of electrical energy. In some aspects, the third block may further comprise one or more control components that initiate the current supply or regulate the current from the electric power source. According to another aspect, the second block may comprise one or more control components that initiate the current supply or regulate the current flowing from the electric power source of the third block. According to yet another aspect, the second and third blocks may comprise one or more control components that initiate the current supply and regulate the current flowing from the electric power source of the third block to the resistive heating element of the second block.

According to another aspect, any of the first, second and/or third units may comprise one or more control components that initiate the current supply and regulate the current flowing from the electric power source to the resistive heating unit. The first unit may have a distal end that interacts with the second unit and an opposite proximal end that forms a mouthpiece (or simply a tip) with an opening at its proximal end. In another aspect, the first unit may have a distal end that interacts with the third unit and an opposite proximal end that forms a mouthpiece (or simply a tip) with an opening at its proximal end. The first unit, the second unit and/or the third unit may comprise an air or internal channel in the mouthpiece of the first unit and this air channel may ensure the passage of an aerosol generated by heat from the resistive heating element into the mouthpiece. In one aspect, the first unit may be disposable, while the second and third units may be reusable. According to another aspect, the first, second and third blocks may be intended for multiple use.

In particular, a smoking article according to one aspect of the present invention may have a reusable tubular body that has a substantially cylindrical shape, wherein the reusable tubular body has a first end and an opposite second end. In some aspects, the first end may be an end of interaction with the mouthpiece, and the opposite second end may be an end of interaction with the component body. The smoking article may further comprise a reusable component body or a portion of the power source that has a substantially cylindrical shape and also has a first end and an opposite second end. In some aspects, the first end may be an end interacting with the tubular body, and the second end of the reusable component body or the portion of the power source may be an opposite distal end that may include one or more indicators of active use of the smoking article. The end of the component body interacting with the tubular body may be configured to operatively connect the power source inside the component body to the tubular body containing a heating element (i.e. a resistive heating element). The article may further comprise a reusable or disposable mouthpiece section, which has a substantially cylindrical shape and also has a first end and an opposite second end. According to some aspects, the first end may be an end inserted into the mouth for performing a puff using the article, and the opposite second end may be an opposite end interacting with the tubular body, configured to connect the mouthpiece section to the tubular body. In order to use the smoking article, the consumer may connect the power source inside the component body to the tubular body containing the heating element, place the aerosol-generating element inside the tubular body, providing functional interaction with the heating element, and connect the mouthpiece section to the tubular body to close the heating element and the aerosol-generating element. In some aspects, the corresponding interacting ends of the mouthpiece section, the tubular body and the component body may comprise mating threaded surfaces for screw interaction. In other aspects, the interacting ends of the various housings and/or mouthpiece sections may have a clamping interaction, a magnetic interaction, or any other suitable type of interaction that allows the various sections and/or housings to be held in interaction with each other.

A smoking article according to another aspect of the present invention may comprise a reusable tubular body which has a substantially cylindrical shape, wherein the reusable tubular body has a first end and an opposite second end. In some aspects, the first end may be an end of interaction with the component body, and the opposite second end may be configured to accommodate an aerosol generating element therethrough. In some aspects, the opposite second end of the reusable tubular body may be configured to operatively interact with the end cap body. The smoking article may further comprise a reusable component body or a portion of the power source which has a substantially cylindrical shape and also has a first end and an opposite second end. In some aspects, the first end may be an end of interaction with the mouthpiece, and the opposite second end of the reusable component body or portion of the power source may be configured to operatively interact with the end of the tubular body interacting with the component body and/or operatively interact with the end cap body. In some aspects, the end cap housing and the component housing or the power source portion may be configured at least partially to fully and/or partially close the tubular housing between them and/or them. The end of the component housing interacting with the tubular housing may be configured to operatively connect the power source inside the component housing to the tubular housing, which in some aspects may comprise a heating element (i.e., a resistive heating element). In another aspect, the component housing may be configured to receive a portion of the tubular housing, and may also be configured to operatively connect the power source inside the component housing to a portion of the heating element (i.e., a resistive heating element), which is configured to operatively interact with the tubular housing. The article may further comprise a reusable or disposable mouthpiece portion, which has a substantially cylindrical shape and also has a first end and an opposite second end. According to some aspects, the first end may be an end inserted into the mouth for performing a puff using the article, and the opposite second end may be an opposite end interacting with the component body, configured to connect the mouthpiece portion to the component body. In order to use the smoking article, the consumer may connect the power source inside the component body to at least one portion of the heating element configured to be received inside the tubular body. In some aspects, the tubular body may include a second portion of the heating element. In another aspect, the consumer may connect the power source inside the component body to the tubular body containing at least one portion of the heating element. Then the consumer may place the aerosol generating element inside the tubular body, providing operative interaction with the heating element, and close the tubular body inside the component body and/or the end cap body to close the heating element and the aerosol generating element. Then the consumer may operatively connect the mouthpiece portion to the component body. In some aspects, the respective interacting ends of the mouthpiece portion, the tubular body, and the component body may comprise mating threaded surfaces for screw interaction. In other aspects, the interacting ends of the various bodies and/or mouthpiece portions may have a clamping interaction, a magnetic interaction, or any other suitable type of interaction that allows the various portions and/or bodies to be held in interaction with each other.

During use, the consumer initiates heating of the heating element, such as, for example, a resistive heating element, and with the help of heat created by the resistive heating element, an aerosol and, in some cases, additional inhalable substances are generated from the aerosol generating element. Such heating releases at least a portion of the aerosol generating element as an aerosol (which may include any additional inhalable substances contained therein) and such aerosol enters a space associated with the heating element (for example, a heating cavity) within a tubular body that is in fluid communication with the mouth-insertable end of the mouthpiece portion. When the consumer takes a puff from the mouth-insertable end of the mouthpiece portion, air passes through at least one or all of the component housings, the tubular body and the mouthpiece portion and the consumer receives a combination of the drawn air and aerosol when the drawn materials exit the mouth-insertable end of the mouthpiece portion into the consumer's mouth.

To initiate heating, the consumer may press a push-button switch, activate a capacitive sensor or similar component that initiates the heating element to receive electrical energy from a power source (e.g., a battery or other power source, such as a capacitor). In another aspect, the consumer may initiate heating by taking a puff on the mouthpiece end, thereby activating a puff sensor configured to initiate the heating element to receive electrical energy from the power source. Electrical energy may be supplied for a predetermined period of time or its supply may be manually controlled. Preferably, between puffs, the product substantially does not supply electrical energy (although energy may be supplied to maintain a base temperature above the ambient temperature, such as a temperature that allows rapid heating to a high-intensity heating temperature). In other aspects, heating may be initiated by the action of the consumer releasing smoke through the use of various sensors, as described elsewhere herein. After the smoke release ceases, heating will be stopped or reduced. When the consumer has taken a sufficient number of puffs to release a sufficient amount of aerosol and/or inhalable substance (e.g., an amount sufficient to equate to the sensation of conventional smoking), the aerosol generating element can be removed from the heating cavity and discarded. An indication that the aerosol generating element is being consumed (i.e., the aerosol generating element substantially provides a known amount of aerosol that the aerosol generating element can provide to the consumer) can be provided by an indicator or other suitable indicators. In some aspects, one aerosol generating element can provide more than one smoking process and, thus, is capable of providing a sufficient volume of the aerosol generating element to simulate the same amount of conventional cigarettes.

The preceding description of the use of the product can be applied to the various aspects described with minor modifications that may be obvious to those skilled in the art in view of the further description provided in this application. However, the above description of the use does not limit the use of the product according to the present invention, but is presented in order to fulfill all necessary requirements regarding the description of the present invention.

As shown in Fig. 1 and 2, the smoking article 5 according to the present invention may typically comprise a mouthpiece section 10, a tubular body 30 defining a space (i.e., a heating cavity 40) associated with a heating element 37, and a component body 50 that contains a power source. According to some aspects, each of the mouthpiece section 10, the tubular body 30 and the component body 50 may also comprise additional components. In addition, the mouthpiece section 10 may have an end inserted into the mouth 11 (i.e., an end by which the consumer can take a puff to inhale an aerosol from the article) and an end 12 cooperating with the tubular body, which is longitudinally opposite to the end inserted into the mouth. The tubular body 30 may have a first end 31 cooperating with the mouthpiece and a second, opposite in the longitudinal direction, cooperating with the component body end 32, which may be designed to operatively interact with the end 51 of the component body 50 cooperating with the tubular body. As shown in Fig. 1, the end 32 of the tubular body 30 cooperating with the component body may be opposite in the longitudinal direction to the end 31 of the tubular body cooperating with the mouthpiece. The illustrated article is presented as a smoking device with a plurality of components, but any of the mouthpiece section, the tubular body and/or the component body may be formed integrally with any of the other sections. As will be apparent from the further description of the present invention, it may be preferable that aspects of the smoking article are formed from three or more separate sections connected to each other, each of which contains separate components of the smoking article.

The smoking article 5 according to the present invention may have a general shape that may be defined as substantially rod-shaped, substantially tubular or substantially cylindrical. As shown in Fig. 1 and 2, each of the mouthpiece portion 10, the tubular body 30 and/or the component body 50 may have a substantially circular cross-section; however, the present invention also encompasses other cross-sectional shapes (e.g., oval, square, triangular, etc.). In addition, the tubular body 30 may have a substantially circular cross-section and a larger diameter than the diameters of the substantially circular cross-sections of the mouthpiece portion 10 and/or the component body 50. Such wording, which characterizes the physical shape of the smoking article, may also be applied to the article in aspects in which the portions are unified as a single portion and/or less than three separate and separable portions.

The outer shell 13 of the mouthpiece section 10 can be made of any material suitable for forming and maintaining the appropriate shape, such as a tubular shape, and for holding the appropriate components of the mouthpiece section in it. Similarly, the outer shell 33 of the tubular body 30 can be made of any material suitable for forming and maintaining the appropriate shape, such as a tubular shape, and for holding the appropriate components of the tubular body in it. In addition, the outer shell 53 of the component body 50 can also be made of any material suitable for forming and maintaining the appropriate shape, such as a tubular shape, and for holding the appropriate components of the component body in it. According to some aspects, the outer shells 13, 33, 53 can be made essentially of the same material. In some aspects, the outer shells 13, 33, 53 can be made of a material (natural or synthetic) that is heat-resistant to maintain its structural integrity (e.g., the materials do not deteriorate when exposed to heat) at least at a heating temperature provided by the resistive heating element, as described further herein. In some aspects, a heat-resistant polymer can be used. In other aspects, ceramic materials can be used. In specific aspects, the outer shells 13, 33, 53 can consist of a material made of stainless steel and/or other metallic materials. According to some aspects, the outer shell 33 of the tubular body 30, if formed from a single layer, can have a thickness of from about 0.2 mm to about 5.0 mm, from about 0.5 mm to about 4.0 mm, from about 0.5 mm to about 3.0 mm, or from about 1.0 mm to about 3.0 mm. Other examples of components and materials that may be used to provide the above-described functions or may be used as alternatives to the above-described materials and components are described in U.S. Patent No. 8,464,726 (Sebastian et al.), the disclosure of which is incorporated herein by reference in its entirety.

As shown in Fig. 1 and 2, the smoking article 5 may comprise a component body 50 comprising an end 51 cooperating with the tubular body and a distal end 52 which are longitudinally opposed to each other. As shown in Fig. 2, the end 51 of the component body 50 cooperating with the tubular body comprises an interaction element 54 on an outer surface of the component body configured to interact and/or operatively connect the component body 50 with the tubular body 30 for use. In some aspects, the interaction element 54 may comprise a threaded surface configured to screw-like interact with a mating interaction element 36 (for example, a mating threaded surface configured to interact with a threaded surface of the interaction element 54) of the tubular body 30. In another aspect, the interaction element 54 and the mating interaction element 36 may have a clamping interaction; however, the present invention also encompasses other types of interaction elements (e.g., magnets, snap-on connections, etc.).

In some aspects, at least one internal passage 56 may be formed in the component housing 50 to allow air to be drawn through it and into the tubular housing 30. In particular, at least one internal passage 56 may also be formed in the component housing 50 in some cases, configured to communicate via a fluid medium with the tubular housing 30. In addition, or as an alternative, the tubular housing 30 may comprise a wall element 41 that extends laterally between the outer wall 34 and the inner wall 35 of the tubular housing, as described in more detail elsewhere in this document. At least one opening may be formed in the wall element 41, configured to provide an air passage in the heating cavity 40, which is also described in more detail elsewhere in this document. In some cases, at least one opening may be arranged and configured to connect and communicate via fluid with at least one internal channel 56 formed in the component housing 50 to ensure that air is drawn through it and into the heating cavity 40 through at least one opening. In addition, one or more internal channels 56 may also communicate via fluid through the heating cavity 40 with the channel 14 of the mouthpiece. Accordingly, air, when it is drawn through the mouth-insertable end 11 of the mouthpiece portion 10, in turn, may be drawn through at least one internal channel 56 for fluid of the component housing 50, through at least one opening formed by the wall element 41, into the heating cavity 40 of the tubular housing 30 and through the channel 14 of the mouthpiece into the mouth-insertable end of the mouthpiece portion. Thus, according to some aspects, the heating cavity 40 may be configured to release an aerosol (which may include any other inhalable substances included therein) from the aerosol generating element 70 and through the mouthpiece channel 14 into the mouth-insertable end of the mouthpiece portion in response to a puff being taken.

In addition, the article 5 may comprise one or more status indicators or other indicators located on any one of the outer casings 13, 33, 53 or on casings that are a combination of said casings. Such indicators, as discussed above, may indicate the number of puffs performed or that can still be performed using the article, may indicate an active or inactive state, may light up in response to the execution of a smoke release, a puff and/or the like. According to one aspect, the indicator may be located near the component housing 50 and may be configured to provide an indication of the amount of energy remaining inside the battery 55. The present invention also encompasses the use of any number of indicators or other indicators, and these indicators or other indicators may be associated with an opening in the casing, through which an audible warning may be issued if necessary.

According to some aspects of the present invention, the component housing 50 may further comprise a power source, such as a battery 55, and at least one electronic control unit (not shown), wherein these components may be arranged in various orders within the component housing 50. Although not explicitly shown, it is understood that the smoking article 5, and the component housing 50 in particular, may comprise wires or other conductive means if necessary to supply electric current from the battery 55 to additional components and to connect the components to ensure the proper performance of the necessary functions provided for the smoking article 5. For example, the smoking article 5 may comprise wires (not shown) within the component housing 50 and/or the tubular housing 30 if necessary to supply electric current from the battery 55 of the component housing 50 to the heating element 37 located within the tubular housing 30. According to another aspect of the present invention, the smoking article may comprise wires or other conductive means (not shown) within the component housing 50 and/or the tubular housing 30, if this is necessary to supply electric current from the battery 55 of the component housing 50 to one or more status indicators and/or other indicators located on any one of the outer shells 13, 33, 53 or on shells that are a combination of the said shells, and/or located in any of the mouthpiece section 10, tubular housing 30 and/or component housing 50.

As shown in Fig. 2, the smoking article 5 may comprise a mouthpiece section 10 which comprises an end interacting with the tubular body, configured to interact and/or operatively connect the mouthpiece section with the end 31 of the tubular body 30 interacting with the mouthpiece. According to another aspect of the present invention, the end 31 of the tubular body 30 interacting with the mouthpiece may comprise an interaction element 17 configured to ensure interaction and/or operative connection of the tubular body with the mouthpiece section 10.

In some aspects, the interaction element configured to provide interaction and/or functional connection of the tubular body 30 with the mouthpiece section 10 may provide interaction of a snap-on and/or clamping type. In other cases, a threaded interaction may be implemented. According to some aspects, the tubular body 30 may have a mouthpiece engaging end 31 configured to receive the mouthpiece portion 10 such that the mouthpiece portion engages the aerosol generating element 70, which may be located within the tubular body 30. Thus, the mouthpiece engaging end 31 may be configured such that the mouthpiece portion 10 pushes the aerosol generating element 70 (i.e., close to the biasing element, as discussed in more detail later in this document) into the heating cavity 40 upon engagement between the mouthpiece portion 10 and the tubular body 30.

According to some aspects, the mouthpiece portion 10 may have a substantially cylindrical shape. As shown in Fig. 2, the mouthpiece portion 10 may include a first portion 15 located near the mouth-insertable end 11 and a second portion 16 located near the end cooperating with the tubular body. The air flow channel 14 may extend in the longitudinal direction through both the first portion 15 and the second portion 16 of the mouthpiece portion 10. As shown in Fig. 2, both the first portion 15 and the second portion 16 may have a substantially cylindrical shape. Although both the first portion 15 and the second portion 16 are shown as having substantially circular cross-sections, the present invention also encompasses other cross-sectional shapes (e.g., square, oval, etc.). Furthermore, in Fig. 2 shows that the first portion 15 of the mouthpiece portion 10 has a smaller diameter than the second portion 16. In some aspects, the first portion 15 may have a larger diameter than the second portion 16 of the mouthpiece portion. In another aspect, the first portion 15 may have a diameter substantially similar to the diameter of the second portion 16. However, Fig. 2 shows that the second portion 16 of the mouthpiece portion has a largest diameter that is substantially similar to the largest diameter of the shell of the tubular body 30. Thus, when the mouthpiece portion 10 operatively interacts with the tubular body 30, this interaction provides a precise mating between the mouthpiece portion and the tubular body. Furthermore, in some aspects, the mouthpiece portion 10 may comprise a material that is substantially heat-resistant. In some aspects, the mouthpiece portion 10 may comprise a stainless steel material. In some aspects, the heat generated by the heating element 37 within the heating cavity 40 may be sufficient to generate an aerosol from the aerosol generating element, while the mouthpiece portion 10 remains relatively cooler.

As shown in Fig. 2, the smoking article 5 may comprise a tubular body 30 that has a mouthpiece-engaging end 31 and a longitudinally opposite component-engaging end 32. The component-engaging end 32, according to one illustrative aspect, comprises a mating interaction element 36 that is configured to provide interaction and/or functional connection of the tubular body 30 with the tubular-engaging end of the component body 50, as discussed above.

According to some aspects of the present invention, the tubular body 30 may contain electrical conductors, if necessary, to form an electrical circuit with the battery 55 and the heating element 37. In addition, the tubular body 30 may contain corresponding electrical conductors so that the electrical circuit is operative when the tubular body 30 is operatively connected to both the mouthpiece portion 10 and the component body 50. In some cases, the electrical circuit may operate only when the aerosol generating element 70 is located in the heating cavity 40 of the assembled article. In some aspects, the heating element 37 may be electrically connected to the battery 55 by means of corresponding wires or corresponding electrical conductors passing between the terminals of the battery and the heating element 37, to ensure the formation of an electrical circuit configured to selectively control the current flow through the heating element, such as, for example, a resistive heating element. In particular aspects, the article 5 may comprise an electrical circuit, in which at least one control component associated with the electrical circuit supplies, controls or otherwise modulates energy from the battery 55 to supply energy to the heating element 37 according to one or more specific algorithms. Such an electrical circuit may, in particular, comprise a flow sensor (not shown), so that the article 5 is activated only when a puff is performed (i.e., during use by a consumer puffing through the mouthpiece 10). For example, the flow sensor may be configured to detect the consumer's puffing of smoke or the product's taking a drag, and then send a signal to activate the control component to supply power from the battery 55 to the heating element 37 so that the heating element generates heat that is to be supplied to the element 70 to generate an aerosol inside the heating cavity 40, wherein the aerosol-generating element, in turn, upon receipt of heat forms and provides an aerosol, wherein this aerosol is suitable for inhalation by the consumer. The control algorithm may, for example, initiate the supply of power to the heating element 37 according to a certain cycle to maintain a certain temperature on the heating element. The control algorithm may also be programmed to automatically deactivate or stop supplying power to the heating element 37 if no puffing or puffing of smoke is detected on the product for a certain period of time.

According to some aspects, the article may comprise a temperature sensor configured and arranged to provide feedback to the control component. Such a temperature sensor may, for example, directly contact the heating element 37 or may be located together with the heating cavity 40 near the aerosol generating element 70 (i.e., in such a way that the heating element can be controlled by the controller to maintain heat near the aerosol generating element with the desired temperature for forming the aerosol). In addition, alternative temperature measuring means may be used, such as, for example, components for implementing logical control for the purpose of estimating the resistance on the resistive heating element and correlating this resistance with the temperature of the heating element 37. In other aspects, the flow sensor may be replaced with alternative measuring means, such as capacitance measurement, as described elsewhere in this document. As already indicated in this document, any number of sensors and combinations thereof may be used. In addition, to ensure manual activation by the consumer of various functions, such as switching on and off the product 5, switching on the heating element 37 to generate an aerosol for inhalation and/or the like, one or more control buttons may be used.

As already discussed in this document, the smoking article 5 may comprise a heating element 37 configured to supply heat to a heating cavity 40 defined by and within the tubular body 30. For example, the smoking article may comprise wires (not shown) within the component body 50 and/or the tubular body 30 for supplying electric current to the heating element 37, such as, for example, a resistive heating element located within the tubular body 30, which is configured to supply heat to the heating cavity 40 defined by the outer wall 34 and the inner wall 35. In some aspects, the tubular body 30 comprises a first or outer wall 34 that has a substantially cylindrical shape. Furthermore, the tubular body 30 comprises a second or inner wall 35 that also has a substantially cylindrical shape. As shown in Fig. 2, the outer wall 34 and the inner wall 35 may be concentrically aligned with respect to the longitudinal axis A. According to one aspect, the inner wall 35 may be substantially cylindrical in shape and may have a radius that is smaller than a radius defined by the substantially cylindrical shape of the outer wall 34, such that the space extending laterally between the outer wall 34 and the inner wall 35 forms the heating cavity 40. In some aspects, the tubular body 30 may comprise an outer wall 34 and an inner wall 35 that may have a tapering shape such that the distance between the outer wall 34 and the inner wall 35 is smaller when measured closer to the end 32 interacting with the component body compared to the distance between the outer and inner walls when measured closer to the end 31 interacting with the mouthpiece. Although in FIG. 2 shows a heating cavity 40 having a substantially hollow cylindrical shape formed between an outer wall 34 and an inner wall 35, the present invention also covers other suitable shapes (e.g., hollow, square, conical, etc.). According to some aspects, the outer wall 34 and the inner wall 35 may comprise a heat-conducting material suitable for transferring heat into the heating cavity 40. For example, the outer wall 34 and the inner wall 35 may comprise a stainless steel material and/or another metallic material suitable for transferring heat into the heating cavity.

As mentioned earlier, a substantially hollow cylindrical shape can be formed between the outer wall 34 and the inner wall 35. Furthermore, according to some aspects, the outer wall 34 and the inner wall 35 can additionally or alternatively have ends that are opposite in the longitudinal direction, wherein one of the ends that are opposite in the longitudinal direction includes a wall element 41 that extends in the lateral direction between the outer wall 34 and the inner wall 35, as shown in Fig. 2 and as discussed earlier in this document. According to some aspects of the present invention, the wall element 41 can be located near the end 32 of the tubular body 30 that interacts with the component housing.

According to some aspects of the present invention, the tubular body 30 may further comprise a biasing element operatively interacting with one of the outer wall 34, the inner wall 35 and/or the wall element 41 of the heating cavity 40. The biasing element may be configured to provide a biasing force for biasing the aerosol generating element 70 outwardly from the heating cavity 40 when the mouthpiece portion 10 is detached from the tubular body 30. For example, the biasing element may be operatively interacting with the wall element 41 and may be configured to apply a biasing force to the aerosol generating element 70 in a longitudinal direction outwardly from the heating cavity 40. The biasing element may comprise a spring element and/or any suitable means for applying a biasing force to the aerosol generating element in the direction of the mouthpiece interacting end 31 of the tubular body 30 and in a longitudinal direction outwardly from the heating cavity 40 when detaching the mouthpiece section 10 from the tubular body.

As mentioned earlier, the tubular body 30 may comprise a heating element 37 configured to supply heat to the heating cavity 40. In some aspects, the heating element 37 may be configured to supply heat to the heating cavity 40 when powered by a power source, such as a battery 55. In some cases, the heating element 37 may include a resistive heating element, although other types of heating elements (i.e., induction, microwave, radiant, etc.) may also be implemented if necessary. According to some aspects, the heating element 37 may comprise a coiled portion 38 and an elongated portion 39, as shown in Figs. 3A and 3B.

In the aspect illustrated in Fig. 3A, the heating element 37 may be configured to be functionally received by the wall element generating the heating cavity 40. For example, the heating element 37 may comprise a helical or spiral-shaped portion 38 with an additional portion 39 in the form of an elongated element extending near the spiral-shaped portion 38 and longitudinally along the central axis of the spiral-shaped portion. Thus, the spiral-shaped portion 38 may be configured to extend in the longitudinal direction around the outer wall 34 generating the heating cavity 40, and the portion 39 in the form of an elongated element may be configured to extend in the longitudinal direction inside and along the inner wall 35 of the heating cavity. In some aspects, the section 39 in the form of an elongated element may also extend in the longitudinal direction along the central axis about which the section 38 formed in the form of a spiral rotates. Thus, the heating element 37 may be configured to supply heat to the heating cavity 40 both in the lateral direction through the outer wall 34 and in the lateral direction through the inner wall 35. According to some aspects, the section 39 in the form of an elongated element may be designed not as a rod-shaped element, but in another desired way. For example, the section 39 in the form of an elongated element in some cases may be designed as a section twisted into a spiral or helical, as shown in Fig. 3B. Accordingly, one aspect of the present invention includes a heating element 37 comprising a section 38 formed in the form of a spiral, which rotates about an axis, and a section 39 in the form of an elongated element, which is designed as a section twisted into a spiral or helical, which also rotates about the same axis.

According to some aspects, the spiral-shaped portion 38 may be formed integrally with the elongated portion 39 to form a single heating element 37, as shown in Figs. 3A and 3B. In one aspect, a first portion (e.g., the spiral-shaped portion) of the heating element may be arranged in series with a second portion (e.g., the elongated portion) of the heating element. According to another aspect, the first portion of the heating element may be arranged parallel to the second portion of the heating element. In yet another aspect, the spiral-shaped portion 38 and the elongated portion 39 may be separate portions of the heating element that may be configured to be separately controlled to supply heat to the heating cavity 40. Thus, the spiral-shaped portion 38 may be activated to supply heat to the heating cavity 40, while the elongated portion 39 may remain in the off state. Alternatively, the section 39 in the form of an elongated element can be activated to supply heat to the heating cavity 40, while the section 38 in the form of a spiral can remain in the switched-off state. In addition, the section 38 in the form of a spiral can be controlled by a control unit to supply heat to the heating cavity 40 at a certain temperature, while the section 39 in the form of an elongated element can be controlled by the same or another control unit to supply heat to the heating cavity at the same or another temperature.

Aspects of the present invention preferably provide for significant and uniform heating of the aerosol-generating element by providing a plurality of heating elements or a heating element comprising a plurality of sections located inside the tubular body 30. In particular, a smoking article according to one aspect comprises a heating element 37 that comprises a section 38 made in the form of a spiral, which is located near the outer wall 34, which provides heating for the outermost radial sections of the aerosol-generating element 70, while a section 39 in the form of an elongated element provides heating of the radial sections of the aerosol-generating element closest to the central axis. Accordingly, the heating element 37 can preferably provide heating of the aerosol-generating element 70 radially inward from the outer wall 34 and simultaneously heating of the aerosol-generating element radially outward from the inner wall 35.

According to some aspects, at least a portion of the heating element 37 may be located near the wall element 41. In some aspects, the heating element 37 may comprise a portion of the heating element located near the wall element 41 that operatively connects the spiral-shaped portion 38 to the elongated portion 39. Accordingly, the heating element 37 may advantageously provide for heating the aerosol-generating element 70 longitudinally inward from the wall element 41 simultaneously with heating the aerosol-generating element radially inward from the outer wall 34 and heating the aerosol-generating element radially outward from the inner wall 35.

In the manufacture of the smoking article, the aerosol generating element 70 is inserted into the heating cavity 40 to enable it to be heated by the heating element 37. According to one aspect of the present invention, the aerosol generating element 70 may be solid tobacco particles and/or a tobacco-related material that has a shape and configuration (i.e., a permanent hollow cylindrical shape shown in Fig. 4A) that ensures its reception into the heating cavity 40. As shown in Figs. 4A-4G, the aerosol generating element 70 may be made in various shapes and configurations that ensure its introduction and reception into the heating cavity 40. In the case of using a permanent hollow cylindrical shape of the aerosol generating element 70, the aerosol generating element may be manufactured in a continuous process, such as, for example, an extrusion process. Furthermore, in the case of using a permanent hollow shape shown in Fig. 4E-4G, the aerosol generating element can be manufactured by a continuous process, such as, for example, an extrusion process.

In another aspect, the heating cavity 40 can be formed by a substantially cylindrical inner wall 35 and a tapering cylindrical outer wall 34 so that the corresponding aerosol generating element 70 is designed as a tapering hollow cylinder, shown in Fig. 4B. Thus, the surface 72 of the aerosol generating element 70, which interacts with the wall element 41, formed by the heating cavity 40 over the aerosol generating element inserted into the heating cavity 40, can have a smaller diameter than the opposite surface 71 of the aerosol generating element. In addition, the inner surface 75 of the aerosol generating element 70 can be substantially cylindrical, while the outer surface 74 of the aerosol generating element can be tapering in one longitudinal direction. Although such a tapered shape may facilitate removal of the aerosol generating element from the heating cavity, an aerosol generating element having such a shape cannot be manufactured in a continuous process (i.e., by extrusion), and in this case the aerosol generating element may be manufactured in the form of separate units in a discrete process, such as, for example, molding or casting.

According to one aspect, the inner wall 35 of the tubular body may be tapered, while the outer wall 34 remains substantially cylindrical such that the surface 72 of the aerosol generating element 70, which contacts the wall element 41, has a smaller cross-sectional area than the cross-sectional area of the opposite surface 71 of the aerosol generating element 70, as shown in Fig. 4C. Thus, the inner surface 75 of the aerosol generating element 70 may be tapered in one longitudinal direction, while the outer surface 74 remains substantially cylindrical. According to another aspect, the inner surface 75 of the aerosol generating element 70 may be substantially formed in the form of a heptagram, as shown in Fig. 4F and 4G.

In another aspect, both the outer wall 34 and the inner wall 35 of the heating cavity may be tapered in opposite longitudinal directions such that the corresponding aerosol generating element 70 shown in Fig. 4D comprises a surface 72 having a smaller cross-sectional area than the cross-sectional area of the opposite surface 71 of the aerosol generating element 70. Furthermore, as shown in Fig. 4D, the surface 72 may have a smaller diameter than the opposite surface 71. Accordingly, when the aerosol generating element 70 of the corresponding shape is inserted into the heating cavity defined by the tapering shape of the outer wall 34 and the inner wall 35 in opposite longitudinal directions, the tapering shape of the outer wall and the inner wall facilitates the removal of the aerosol generating element 70 from the heating cavity, since the opposite tapering inner and outer walls provide minimal resistance and/or contact with the aerosol generating element when removing the aerosol generating element from the heating cavity. Although the aerosol generating elements shown in Figs. 4A-4G illustrate various shapes, typically hollow cylinders, the present invention also includes other shapes, such as, for example, a hollow cuboid, a hollow parallelepiped, and/or the like.

As shown in Fig. 4E and 4G, the aerosol generating element 70 can be substantially formed as a hollow prism with a heptagram cross-section. In some embodiments, if the aerosol generating element 70 in the form of a prism with a heptagram cross-section is inserted into the heating cavity 40, as shown in Fig. 11, the outer surface 74 of the aerosol generating element can contact the outer wall 34 of the heating cavity to provide an internal space or chamber for forming an aerosol and/or an internal channel 42 for moving the formed aerosol from the heating cavity 40 to the channel 14 of the mouthpiece. According to some aspects, the use of an aerosol generating element 70 in the form of a prism with a heptagram cross-section may also provide for an increase in the area of the outer surface 74 of the aerosol generating element that is acted upon by the heating element in order to produce an aerosol for consumption. As mentioned earlier, the aerosol generating material 70 may include solid tobacco particles and/or a tobacco-related material and may be molded and/or formed as a hollow cylindrical extrudate, as shown in Fig. 4A, containing solid materials, such as tobacco, a tobacco component, or a material derived from tobacco (i.e., a material that is naturally present in tobacco and that can be directly isolated from tobacco or synthetically prepared). The tobacco used may include (or be derived from) such tobaccos as flue-cured tobacco, Burley tobacco, oriental tobacco, Maryland tobacco, dark tobacco, dark fire-cured tobacco and shag, as well as other rare or special tobaccos or mixtures thereof. In another aspect, the aerosol generating material 70 may include solid tobacco particles and/or a tobacco-related material, as well as an additional flavoring substance and/or another material that modifies the sensory or organoleptic properties or the properties of the main aerosol of the smoking article. Such flavoring substances may be obtained from starting materials other than tobacco, and may be natural or artificial in nature. In some aspects, the flavoring substances may be applied to the aerosol generating element 70 and/or those areas of the smoking article in which the aerosol is formed (i.e., the heating cavity 40), or introduced into them. Although the flavoring agents may be directly applied to the aerosol generating material 70 and/or the heating cavity 40, in some aspects the flavoring agent may be provided by a separate substrate located near the aerosol generating materials 70 and/or near the heating cavity 40. Examples of flavoring agents include vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors, including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, as well as packaged flavoring agents and additives characterized by a certain type and nature that are traditionally used for flavouring tobaccos for cigarettes, cigars and pipes. In addition, syrups such as high fructose corn syrup may be used. Flavouring agents may also include substances with acidic or basic characteristics (e.g. organic acids such as levulinic acid, succinic acid and pyruvic acid).

As shown in Fig. 4A-4G, the aerosol generating element 70 may comprise a longitudinal channel 73 extending from a first surface 71 to an opposite second surface 72. In some aspects, when the aerosol generating element 70 is inserted into the heating cavity 40, the second surface 72 may be located near the wall element 41. The longitudinal channel 73 may be configured to receive at least a portion of the elongated element portion 39 of the heating element 37. According to some aspects, the longitudinal channel 73 may be formed in the form of a cylindrical channel, as shown in Fig. 4A. As shown in Fig. 4F and 4G, the longitudinal channel 73 may be a heptagram-shaped channel, which may be configured to receive at least a portion of the elongated element portion 39 of the heating element 37. As shown in Fig. 11, the longitudinal channel 73 in the form of a heptagram can provide an increase in the area of the inner surface 75 of the element 70 for generating an aerosol, which is affected by the heating element, in order to obtain an aerosol for consumption. In addition, the longitudinal channel 73 in the form of a heptagram can also provide an inner space or chamber for generating an aerosol and/or an inner channel 43 for moving the formed aerosol from the heating cavity 40 to the channel 14 of the mouthpiece. According to some aspects, the longitudinal channel 73 in the form of a heptagram can also provide an increase in the area of the inner surface 75 of the aerosol-generating element, which is exposed to the heating element, in order to obtain an aerosol for consumption.

Fig. 10A-10C illustrate exemplary aerosol generating elements according to various aspects of the present invention. In particular, as shown in Fig. 10A-10C, the aerosol generating element 70 may comprise a longitudinal channel 73 extending from a surface located near the wall element when the aerosol generating element is inserted into the heating cavity of the tubular body in a direction opposite to the surface 71. The longitudinal channel 73 may be configured to receive at least a portion of the second portion (for example, the portion in the form of an elongated element) 39 of the heating element 37. As shown in Fig. 10A and 10C, the aerosol generating element 70 may be formed as a hollow cylindrical extrudate. In Fig. 10A shows an aerosol generating element 70 formed as a hollow cylindrical extrudate of tobacco and/or tobacco-related material corresponding to and received by the hollow cylindrical cavity. Fig. 10C shows an aerosol generating element 70 formed as a hollow cylindrical extrudate of a plurality of microcapsules, each of which comprises a tobacco-related material and a binder, for substantially forming the plurality of microcapsules into a structure corresponding to and received by the hollow cylindrical cavity. Fig. 10B shows another aerosol generating element 70 according to one aspect, in which the aerosol generating element comprises reconstituted tobacco material that is formed into a sheet material that is then wound around a longitudinal channel 73 to form a substantially hollow cylindrical shape corresponding to and received by the hollow cylindrical cavity.

In other aspects, as shown in Fig. 10D and 10E, the aerosol generating element may comprise at least one first region 1071 that comprises tobacco and/or tobacco-related materials (e.g., a mixture of flavored and aromatic tobaccos in the form of cut filler), and at least one second region 1072 that comprises a plurality of microcapsules, each of which comprises a tobacco-related material (e.g., an extract obtained from tobacco), dispersed in a binder configured to substantially maintain a hollow cylindrical structure corresponding to and received by the hollow cylindrical cavity. In one aspect, as shown in Fig. 10D, the aerosol generating element 70 may comprise a plurality of first regions 1071 and a plurality of second regions 1072 that are substantially arranged in the form of corresponding wedge-shaped regions of the substantially hollow cylindrical aerosol generating element 70. Fig. 10E illustrates another exemplary aspect of an aerosol generating element 70 that comprises at least one first region 1071 and at least one second region 1072. In some aspects, at least one first region 1071 may comprise tobacco and/or tobacco-related materials (e.g., a mixture of flavored and aromatic tobaccos in the form of cut filler), and at least one second region 1072 may comprise a plurality of microcapsules, each of which comprises a tobacco-related material (e.g., an extract obtained from tobacco) dispersed in a binder configured to substantially maintain a hollow cylindrical structure corresponding to and received by a hollow cylindrical cavity. Furthermore, in some aspects, the aerosol generating element 70, as shown in FIG. 10E, can be implemented as a multi-segment aerosol generating element, in which the first surface of at least one first portion 1071 is located near the opposite surface of at least one second portion 1072. In other words, the first portion 1071 and the second portion 1072 of the aerosol generating element 70 can be arranged such that the first surface of the first portion substantially adjoins the second surface of the second portion to form a "two-tier" aerosol generating element. According to some aspects, the original aerosol generating element 70 can include an identifying component configured to identify the aerosol generating element as an original and genuine aerosol generating element. For example, in one aspect, the identifying component may include a specially shaped element formed on the aerosol-generating element in such a way that the insertion of the aerosol-generating element into the heating cavity 40 may be performed and completed only when the aerosol-generating element with the specially shaped element is inserted into the heating cavity 40. For example, the surface 72 of the aerosol-generating element 70 may have a recess located at a certain location. In addition, the wall element 41 defining the heating cavity 40 may comprise a corresponding projection that is configured to interact, mate and/or operatively connect with the recess on the surface 72 of the aerosol-generating element. In this way, only original aerosol-generating elements comprising the authenticating element of a certain shape may be completely inserted inside the heating cavity. According to another aspect, a protrusion may be formed on the outer wall 34 and/or the inner wall 35, which extends in the longitudinal direction from the wall element 41 to the opposite end of the hollow cylinder. Thus, the original aerosol generating element 70 may comprise a corresponding channel formed by the outer surface 74 and/or the inner surface 75, configured to interact, couple and/or functionally connect the original aerosol generating element with the longitudinal protrusion formed on the outer wall 34 and/or the inner wall 35 generating the heating cavity. Thus, any formed distinctive features, elements, protrusions, channels and/or the like of the aerosol generating element may act as an authenticating means for the smoking article in the aspect that only an original and suitably shaped aerosol generating element may be used with the smoking article according to the present invention. For example, longitudinally extending projections formed on the outer wall and/or the inner wall, a projection extending from the wall element 41, and/or a physical element of any other suitable shape may be configured to interact with a control unit configured to be activated in response to a functional interaction between a suitably shaped physical element and an element of a corresponding shape and/or a portion of the aerosol generating element such that the control unit can activate a power source with a heating element only when the suitably shaped physical element functionally interacts with the element of a corresponding shape and/or a portion of the aerosol generating element.

In some aspects, the aerosol generating element 70 may further comprise an identifying component configured to electronically interact with any of the control units of the smoking article to authenticate the aerosol generating element as a genuine and original aerosol generating element. For example, the identifying component may include a conductive element configured to operatively interact with a circuit associated with any of the control units of the smoking article. Thus, when the aerosol generating element 70, which includes such a conductive identifying component, is inserted into the heating cavity, the control unit of the smoking article may be configured to be activated in response to the operative interaction between the conductive element of the identifying component and the circuit associated with the control unit. In some aspects, the control unit configured to provide functional interaction of the power source with the heating element 37 may be further configured to provide an electric current flow through the heating element 37 only when the aerosol generating element, which comprises such a conductive identifying component, is inserted into the heating cavity and operatively interacts with the circuit associated with the control unit. According to one aspect, the identification component may comprise a radio frequency identification element configured to electronically interact with any of the control units of the smoking article. Thus, the control unit may be configured to functionally interact the power source with the heating element 37 to provide an electric current flow through the heating element only after the control unit establishes communication, verifies and/or authenticates the aerosol generating element, which has been inserted into the heating cavity 40, using the radio frequency identification element associated with it.

Of course, it will also be obvious to a person skilled in the art that the present invention can also be related to corresponding methods. In one aspect, as shown in Fig. 5 and 6, such a method may include a method for producing an electronic smoking article. Such a method may include interacting a component housing containing a power source with a first end or a longitudinally opposite second end of a tubular housing that includes an outer wall that forms a cylindrical cavity (block 501).

In addition, the method may include introducing an aerosol generating element into the cylindrical cavity (block 502). The aerosol generating element may be configured to generate an aerosol therefrom when heated. In some aspects, the method may further include interacting the heating element with the tubular body such that the first portion of the heating element extends around the outer wall and the second portion extends inside the cylindrical cavity. According to some aspects, the heating element may be configured to supply heat to the aerosol generating element when the heating element is operatively interacting with the power source, as described above in this document.

According to some aspects, the first or second end of the tubular body opposite the first or second end configured to interact with the component body may be configured to interact with the mouthpiece. In some aspects, the tubular body may further comprise a wall element that extends laterally and radially inwardly from the outer wall. The wall element may be located near the first or second end of the tubular body configured to receive and/or operatively interact with the component body. In one aspect, the method may include interacting the heating element with the tubular body such that the second portion of the heating element extends through the wall element and into the cylindrical cavity.

In addition, in some aspects, the tubular body may comprise concentrically aligned inner and outer walls. The concentrically aligned inner wall may be located inside a cylindrical cavity formed by the outer wall, wherein the inner and outer walls may form a hollow cylindrical cavity between them, having ends opposite in the longitudinal direction. In addition, or as an alternative, the method may include introducing an aerosol generating element into a hollow cylindrical cavity of the tubular body.

According to another aspect, the wall-shaped element may form a central channel that is concentrically aligned with the cylindrical cavity. In one aspect, the method may include introducing a second portion of the heating element through the central channel and into the cylindrical cavity. Thus, the outer wall of the tubular body and the second portion of the heating element may form a hollow cylindrical cavity between them, which is designed to accommodate an aerosol-generating element therein. In addition, or as an alternative, the method may include introducing the aerosol-generating element into the hollow cylindrical cavity of the tubular body formed by the outer wall and the second portion of the heating element.

In addition, at least one opening configured to receive air through the wall element may be formed in the wall element. In one aspect, the method may include interacting the component housing containing the power source with the first end or the longitudinally opposite second end of the tubular housing so as to provide a fluid connection of at least one internal channel formed in the component housing with at least one opening formed in the wall element. In some aspects, the method may include interacting the biasing element with the outer wall or the wall element so that the biasing element is capable of biasing the aerosol generating element outwardly from the cylindrical cavity. In another aspect, the method may include interacting the biasing element with the inner wall, the outer wall or the wall element so that the biasing element is capable of biasing the aerosol generating element outwardly from the hollow cylindrical cavity.

According to another aspect, the aerosol generating element may be formed as a hollow cylinder, which is configured to be inserted into a hollow cylindrical cavity. In addition, or as an alternative, the aerosol generating element may be formed as a hollow cylindrical extrudate of tobacco and/or tobacco-related material, corresponding to the hollow cylindrical cavity and received by it. In some aspects, the method may include inserting an aerosol generating element formed as a hollow cylindrical extrudate of tobacco and/or tobacco-related material, corresponding to the hollow cylindrical cavity and received by the hollow cylindrical cavity.

According to some aspects, the method may further include identifying the aerosol generating element as the original aerosol generating element. In one aspect, the smoking article may comprise a control unit, and the method may further include identifying the aerosol generating element as the original aerosol generating element by interacting the identifying component of the original aerosol generating element with the control unit of the smoking article. According to another aspect, the identifying component may comprise a conductive element, and the method may include interacting the conductive element of the identifying component of the original aerosol generating element with a circuit associated with the control unit, when placing the original aerosol generating element inside the cylindrical cavity. The control unit may be configured to be activated in response to the functional interaction between the conductive element of the original aerosol generating element and the circuit so as to ensure the functional interaction of the power source with a heating element configured to supply heat to the original aerosol generating element.

In another aspect, the identifying component of the original aerosol-generating element may comprise a first physical element configured to operatively interact with a second physical element of the smoking article configured to be coupled. In one aspect, the method may include interaction of the first physical element of the identifying component with a second physical element configured to be coupled, communicating with a control unit when the original aerosol-generating element is inserted into the cylindrical cavity. The control unit may be configured to be activated in response to the operative interaction between the first physical element of the original aerosol-generating element and the second physical element configured to be coupled.

According to some aspects, the method may further include engaging the first end of the mouthpiece with the component body or the tubular body. In some aspects, the mouthpiece may comprise an internal channel that extends in the longitudinal direction from the first end to the opposite second end. According to another aspect, the functional engagement of the first end of the mouthpiece with the component body or the tubular body may provide fluid communication between the internal channel and the cylindrical cavity of the tubular body, as well as at least one opening formed in the wall-shaped element. In addition, or as an alternative, the method may include engaging a conductive element of the mouthpiece with the component body or the tubular body. The conductive element may be configured to engage with the heating element to form a circuit of the heating element. According to some aspects, the method may further include engaging the actuator with the smoking article. The actuator may be configured such that the power source responds to actuation of the actuator by supplying power to the heating element configured to supply heat to the aerosol generating element.

According to another aspect of the present invention, as shown in Fig. 6, a method for producing an aerosol generating element for a smoking article may be provided, which includes extruding tobacco and/or a tobacco-related material in the form of a hollow cylinder to be placed in a heating element extending around the outer surface and inside the inner surface of the hollow cylinder, wherein in response to heat supplied to its inner and outer surfaces by the heating element, aerosol and/or any other inhalable substances are generated in the hollow cylinder (block 601).

In another aspect, an aerosol generating element for a smoking article is proposed. The aerosol generating element may include a hollow cylindrical extrudate of tobacco and/or tobacco-related material to be placed in a heating element extending around the outer surface and inside the inner surface of the hollow cylinder, wherein an aerosol is generated from the hollow cylindrical extrudate in response to heat supplied by the heating element.

As shown in Fig. 7-9C, the smoking article 5 according to the present invention may typically comprise a mouthpiece portion 710, a component body 750 that is configured to receive a power source 755 therein (for example, inside a cavity 759 of the power source), a tubular body 730 that generates space (i.e., a heating cavity 740 or a cylindrical cavity) and an end cap 780. According to some aspects, each of the mouthpiece portion 710, the component body 750, the tubular body 730 and the end cap 780 may also comprise additional components. In addition, the mouthpiece portion 710 may have an end 711 that is inserted into the mouth (i.e., an end by which the consumer can take a puff to inhale the aerosol from the article) and an end 712 that interacts with the component body, which is opposite in the longitudinal direction to the end that is inserted into the mouth. The component body 750 may have a first end 751 that interacts with the mouthpiece and a second end 752 that interacts with the tubular body, which is configured to operatively interact with the end 731 of the tubular body 730 that interacts with the component body. In addition, the end 751 of the component body 750 that interacts with the mouthpiece may be opposite in the longitudinal direction to the end 752 of the component body that interacts with the tubular body. As shown in Fig. 7-9C, the end 731 of the tubular body cooperating with the component body may be opposite in the longitudinal direction to the distal end 732 of the tubular body. According to some aspects, the distal end 732 of the tubular body may be configured to operatively interact with the first end 781 of the end cap cooperating with the tubular body. The illustrated article is shown as a smoking device with a plurality of components, but any of the mouthpiece section, the tubular body of the component body and/or the end cap may be formed integrally with any of the other sections. As will be apparent from the further description of the present invention, it may be preferable that aspects of the smoking article are formed from three or more separate sections, and in some aspects four or more separate sections, connected to each other, each of which comprises separate components of the smoking article.

The smoking article 5 according to the present invention may have a general shape that may be defined as substantially tubular or substantially cylindrical. As shown in Fig. 7-9C, each of the component body 750, the tubular body 730 and/or the end cap 780 may have a substantially circular cross-section; however, the present invention also encompasses other cross-sectional shapes (e.g., oval, square, triangular, etc.). As shown in Fig. 7-9C, the mouthpiece portion 710 may comprise a first portion 715 located near the mouth-insertable end 711 and a second portion 716 located near the end 712 interacting with the component body. Although the second portion 716 of the mouthpiece portion 710 may have a substantially tubular or substantially cylindrical shape, the mouthpiece portion may be tapered such that the substantially cylindrical second portion 716 tapers toward the first portion 715 having a substantially oval cross-section.

As in the previous aspects of the present invention discussed herein, the outer shell of the mouthpiece portion 710, the component body 750, the tubular body 730 and/or the end cap 780 may be made of any material suitable for forming and maintaining a corresponding shape, such as a substantially tubular shape, and for containing therein the corresponding components of each of the mouthpiece portion of the component body, the tubular body and/or the end cap. The outer shells may be formed from substantially the same material. In some aspects, the outer shells may be made of a material (natural or synthetic) that is heat-resistant to maintain its structural integrity (e.g., the materials do not degrade when exposed to heat) at least at a heating temperature provided by the heating element as described herein. In some aspects, a heat-resistant polymer may be used. In other aspects, ceramic materials may be used. In certain aspects, the outer shells may be comprised of stainless steel material and/or other metallic materials.

As shown in Fig. 7-9C, the smoking article 5 may comprise a component body 750 having a mouthpiece-engaging end 751 and a longitudinally opposite tubular body-engaging end 752. In some aspects, the longitudinally opposite tubular body-engaging end 752 may also be configured to operably engage with at least one of the component body-engaging end 731 of the tubular body 730 and/or the component body-engaging end 781 of the end cap 780. As shown in Fig. 8A-8C and 9A-9C, the mouthpiece interacting end 751 of the component body 750 comprises a first interaction element 754 on an inner surface of the component body, configured to interact and/or operatively connect the component body 750 with the mouthpiece 710 for use. In some aspects, the first interaction element 754 may comprise a threaded surface configured to screw-like interact with a mating interaction element 717 (for example, a mating threaded surface configured to interact with a threaded surface of the interaction element 754) of the component body 750.

In some aspects, the tubular body engaging end 752 of the component body 750 may comprise a second engagement element 757 on the inner surface of the component body configured to engage and/or operatively connect the component body 750 to the tubular body 730 for use. In some aspects, the second engagement element 757 may comprise a threaded surface configured to screw-couple with a mating engagement element 736 (for example, a mating threaded surface configured to engage with a threaded surface of the second engagement element 757) of the tubular body 730. In another aspect, the tubular body engaging end 752 of the component body may comprise a third engagement element 758 on the inner surface of the component body configured to engage and/or operatively connect the component body 750 to the end cap 780 for use. In some aspects, the third interaction element 758 may comprise a threaded surface configured to screw-couply engage with a mating interaction element 782 (for example, a mating threaded surface configured to engage with a threaded surface of the third interaction element 758) of the end cap 780. According to some aspects, the second interaction element 757 may have a peripheral perimeter that is smaller than the peripheral perimeter of the third interaction element 758. Accordingly, the mating interaction element 736 of the tubular body 730 is configured to operatively engage with the threaded surface of the second interaction element 757 of the component body 750, but is not capable of operatively engaging with the threaded surface of the third interaction element 758 of the component body due to a difference in the circumferences of the corresponding second and third interaction elements. In addition, the mating element 782 of the interaction of the end cap 780 is formed with a larger peripheral perimeter than the mating element 736 of the interaction of the tubular body such that the mating element 782 of the interaction of the end cap is configured to operatively interact with the threaded surface of the third element 758 of the interaction of the component body, but is not capable of operatively interacting with the threaded surface of the second element 757 of the interaction of the component body 750 having a smaller circumference. In another aspect, the corresponding first, second and third elements 754, 757, 758 of the interaction of the component body 750 and the corresponding mating element 717 of the interaction of the mouthpiece section 710, the mating element 736 of the interaction of the tubular body 730 and the mating element 782 of the interaction of the end cap 780 can have a clamping interaction; however, the present invention also encompasses other types of interaction elements (e.g., magnets, snap-on connections, etc.).

In some aspects, as shown in Fig. 9A, at least one internal channel 756 may be formed on the component body 750, configured to be fluidly connected and to provide fluid communication between the tubular body 730 and the mouthpiece portion 710. In addition, or as an alternative, the tubular body 730 may comprise a wall element 741 that extends laterally and radially inwardly from the outer wall 734. The wall element 741 may be located near the first or longitudinally opposite second end of the tubular body 730. In some aspects, the wall element 741 may be located near the end 731 of the tubular body that interacts with the component body. In the wall element 741, at least one internal channel 742 may be formed passing therethrough, configured to be connected via a fluid medium and to provide fluid communication between the heating cavity 740 and at least one internal channel 756 of the component housing 750. In addition, in the wall element 741, a heating element channel 743 may be formed, which extends from the end 731 of the tubular housing 730 interacting with the component housing to the heating cavity 740. The heating element channel 743 may be configured to receive therethrough a second portion 745 of the heating element 737, as described in more detail elsewhere in this document. At least one internal passage 742 may also be configured to provide fluid communication between at least one opening 783 formed in the end cap 780, which may be configured to connect and communicate in fluid communication with the heating cavity 740, and at least one internal passage 756 of the component housing 750. Additionally or alternatively, at least one mouthpiece passage 714 may be formed in the mouthpiece portion 710, configured to connect and communicate in fluid communication with at least one internal passage 756 formed in the component housing 750. Thus, in response to a puff being taken at the mouth-insertable end 711 of the mouthpiece portion 710, air may in turn be drawn through the opening 783, through the heating cavity 740, through the at least one internal passage 742 formed in element 741 in the form of a wall, through at least one internal passage 756 formed in the component housing 750, and through the mouthpiece passage 714 to the mouth-insertable end of the mouthpiece portion. Thus, according to some aspects, in response to performing a puff, the heating cavity 740 can be configured to release an aerosol (which can include any other inhalable substances included therein) from the aerosol generating element 70 through at least one internal passage 742 formed in the element 741 in the form of a wall, through at least one internal passage 756 formed in the component housing, and through the mouthpiece passage 714 at the mouth-insertable end of the mouthpiece portion.

According to some aspects, the component housing 750 may further comprise a power source cavity 759 configured to receive a power source, such as, for example, a battery 755. In addition, the component housing 750 may comprise a biasing element cavity 761, as shown in Fig. 9B and 9C, configured to receive a second portion 745 of the heating element and/or a biasing element 760 associated therewith. Thus, in one aspect, the second portion 745 of the heating element 737 may be configured to contact and/or communicate with the battery 755 located within the power source cavity 759, when the second portion 745 of the heating element is located within the biasing element cavity 761.

In some aspects, as shown in Fig. 9B and 9C, an opening 753 of the biasing element may also be formed in the component housing 750, which extends from the outer surface of the component housing to the cavity 761 of the biasing element. In addition, the opening 753 of the biasing element is configured to receive therethrough an interacting portion 762 of the biasing element 760. In particular, the interacting portion 762 extends in a radial direction from the biasing element 760 and is configured to pass through the opening 753 of the biasing element formed in the component housing 750. In some aspects, the interacting portion 762 is also configured to extend in a radial direction through the opening 753 of the biasing element and behind the outer surface of the component housing 750.

In addition, the smoking article 5 may comprise one or more status indicators or other indicators located on any one of the outer shells of the mouthpiece portion, the component body and/or the end cap or on shells that are a combination of these shells. As shown in Figs. 8A-8C and 9B-9C, for example, the status indicator 790 may be located on the outer shell of the component body 750 and may be configured to provide indications, as discussed above, corresponding to the number of puffs performed or remaining in the article. In addition, or as an alternative, the indicator 790 may provide additional indications, such as, for example, an indication of an active or inactive state. In another aspect, the indicator 790 may be configured to light up in response to the release of smoke, the performance of a puff, and/or the like. According to one aspect, the indicator 790 may be located near the component housing 750 and may be configured to provide an indication of the amount of energy remaining inside the battery 755 or other power source. The indicator 790 may include, for example, a liquid crystal display or an LED display. The present invention also encompasses the use of any number of indicators or other indicators, and these indicators or other indicators may be associated with an opening in the casing, through which an audible warning may be issued if necessary.

According to some aspects of the present invention, the component housing 750 may also be configured to receive a power source, such as a battery 755, and may also include at least one electronic control unit (not shown), and these components may be arranged in various orders within the component housing 750. Although not explicitly shown, it is understood that the smoking article 5, and the component housing 750 in particular, may comprise wires or other conductive means if necessary to supply electrical current from the battery 755 to additional components and to connect the components in order to ensure the proper performance of the necessary functions provided for the smoking article 5. For example, the smoking article 5 may comprise wires (not shown) within the component housing 50 and/or the tubular housing 730 if necessary to supply electrical current from the battery 755 of the component housing 750 to the heating element 737 located within the tubular housing 730. According to another aspect of the present invention, the smoking article may comprise wires or other conductive means (not shown) within the component housing 750 and/or tubular housing 730, if necessary for supplying electric current from battery 755 of component housing 750 to one or more status indicators and/or other indicators located on any one of the outer shells of mouthpiece section 710, component housing 750 and/or end cap 780 or on shells that are a combination of the said shells, and/or located in any of mouthpiece section, component housing and/or end cap.

As shown in Fig. 7-9C, the smoking article may comprise a mouthpiece portion 710 that comprises a component body engaging end 712 configured to engage and/or operatively connect the mouthpiece portion with a mouthpiece engaging end 751 of the component body 750. According to another aspect of the present invention, the mouthpiece engaging end 751 of the component body 750 may comprise an engagement element configured to engage and/or operatively connect the component body with the mouthpiece portion 710. In some aspects, the engagement element configured to provide engagement and/or operative connection of the component body 750 with the mouthpiece portion 710 may provide engagement of a snap-in and/or clamping type. In another aspect, the interaction element 754 may be implemented with a threaded interaction configured to interact and/or functionally connect the component body with the mating interaction element 717 of the mouthpiece section 710.

In some aspects, the mouthpiece portion 710 may comprise a first portion 715 and a second portion 716. As shown in Fig. 8A-9C, the mouthpiece portion 710 may comprise a first portion 715 located near the mouth-insertable end 711, which has a substantially oval cross-section, and a second portion 716 located near the end 712 interacting with the component body, which has a substantially circular cross-section. Furthermore, as shown in Fig. 8A-9C, the second portion 716 may taper in the direction of the first portion 715 such that the substantially circular cross-section of the second portion may taper to the substantially oval cross-section of the first portion. Although the first portion 715 is shown as having a substantially oval cross-section and the second portion is shown as having a substantially circular cross-section, the present invention also encompasses other cross-sectional shapes (e.g., square, rectangular, etc.). In addition, as shown in Fig. 8A-9C, the second portion 716 of the mouthpiece portion 710 has a largest diameter that is substantially the same as the largest diameter of the component body 750. Thus, when the mouthpiece portion 710 operatively interacts with the component body 750, this interaction provides a precise mating between the mouthpiece portion and the component body. In addition, in some aspects, the mouthpiece portion 710 may comprise a material that is substantially heat-resistant. In some aspects, the mouthpiece portion 710 may comprise a stainless steel material. In some aspects, the heat generated by the heating element 737 within the heating cavity 740 may be sufficient to generate an aerosol from the aerosol generating element 70, while the mouthpiece portion 710 remains relatively cooler.

As shown in Fig. 7-9C, the smoking article 5 may comprise a tubular body 730 that has a component body engaging end 731 and a longitudinally opposite distal end 732. The component body engaging end 731, according to one illustrative aspect, comprises a mating engagement element 736 that is configured to engage and/or operatively connect the tubular body 730 with a tubular body engaging end 752 of the component body 750, as discussed elsewhere herein.

According to some aspects of the present invention, the tubular body 730 may contain electrical conductors, if necessary, to form an electrical circuit with the battery 755 and the heating element 737. In addition, the tubular body 730 may contain corresponding electrical conductors so that the electrical circuit is operative when the tubular body 730 is operatively connected to both the component body 750 and the mouthpiece section 710 (for example, due to the operative connection between the component body 750 and the mouthpiece section 710). In some cases, the electrical circuit can only operate when the aerosol generating element 70 is located in the heating cavity 740 of the assembled article. In some aspects, the heating element 737 may be electrically connected to the battery 755 by means of corresponding wires or corresponding electrical conductors passing between the terminals of the battery and the heating element, to provide the formation of an electrical circuit configured to selectively control the flow of current through the heating element, such as, for example, a resistive heating element. In one aspect, the second portion 745 of the heating element 737 may be electrically connected to the battery 755 by means of direct contact and/or by means of corresponding wires or corresponding electrical conductors passing between the terminals of the battery and the heating element. In addition, or alternatively, the second portion 745 of the heating element 737 may be configured to electrically connect the battery 755 to the first portion 738 of the heating element via corresponding wires and/or corresponding electrical conductors passing between the terminals of the battery, and to the second portion of the heating element, when the second portion 745 of the heating element 737 is inserted through the channel 743 of the heating element and extends inside the heating cavity 740 of the tubular body 730. In some aspects, the smoking article 5 may comprise an electrical circuit, in which at least one control component associated with the electrical circuit supplies, controls or otherwise modulates energy from the battery 755 to supply power to the heating element 737 according to one or more specific algorithms. Such an electrical circuit may, in particular, comprise a flow sensor (not shown), so that the article 5 is activated only when a puff is performed (i.e. during use by a consumer who puffs through the mouthpiece portion 710). For example, the flow sensor may be configured to detect the release of smoke by the consumer or the execution of a puff with the article, and then send a signal to activate the control component for the purpose of supplying power from the battery 755 to the heating element 737 so that the heating element generates heat, which must be supplied to the element 70 for generating an aerosol inside the heating cavity 740. The aerosol-generating element, in turn, upon receipt of heat, forms and provides an aerosol, wherein this aerosol is suitable for inhalation by the consumer. The control algorithm may, for example, initiate the supply of power to the heating element 737 according to a certain cycle in order to maintain a certain temperature on the heating element. The control algorithm may also be programmed to automatically deactivate or cut off power to the heating element 737 if no puff is detected from the product or smoke is emitted for a period of time.

As discussed earlier in this document, the article 5 may comprise a temperature sensor configured and arranged to provide feedback to the control component. Such a temperature sensor may, for example, directly contact the first or second portion of the heating element 737 or may be located together with the heating cavity 740 near the aerosol generating element 70 (i.e., in such a way that the heating element can be controlled by the controller to maintain heat near the aerosol generating element with a temperature required to form an aerosol). In addition, or as an alternative, other temperature measuring means may be used, such as, for example, components for implementing logical control for the purpose of estimating the resistance on the resistive heating element and correlating this resistance with the temperature of the heating element 737.

As already discussed in this document, the smoking article 5 may comprise a heating element 737 configured to supply heat to a heating cavity 740 defined by and within a tubular body 730. For example, the smoking article may comprise wires (not shown) within the component body 750, the tubular body 730 and/or the end cap 780 for supplying electric current to the heating element 737, such as, for example, a first portion of a resistive heating element located within the tubular body and a second portion of a resistive heating element configured to be received within the tubular body, which is configured to supply heat to a heating cavity 740 defined at least in part by a wall element 741 and an outer wall 734. In some aspects, the tubular body 730 comprises a first or outer wall 734 that has a substantially cylindrical shape. As shown in Fig. 9A-9C, the outer wall 734 and the channel 743 of the heating element can be concentrically aligned with respect to the longitudinal axis. Although Fig. 9A-9C shows the heating cavity 740 having a substantially cylindrical shape formed by the outer wall 734, the present invention also covers other suitable shapes (for example, a rectangular parallelepiped, etc.). According to some aspects, the outer wall 734 can comprise a thermally conductive material suitable for transferring heat into the heating cavity 740. For example, the outer wall 734 can comprise a stainless steel material and/or another metallic material suitable for transferring heat into the heating cavity.

As mentioned earlier, the outer wall 734 and the wall element 741 are capable of at least partially forming a substantially cylindrical shape. The wall element 741 may be located near the end 731 of the tubular body 730 that interacts with the component housing. In addition, a heating element channel 743 passing through it may be formed in the wall element 741. According to some aspects, the heating element channel 743 may be configured to receive a second portion 745 of the heating element 737 through it.

According to some aspects of the present invention, the tubular body 730 may further comprise a biasing element operatively interacting with one of the outer wall 734 and/or the element 741 in the form of a wall of the heating cavity 740. According to another aspect of the present invention, as shown in Fig. 8B, 8C, 9B and 9C, the smoking article 5 may comprise a biasing element 760 configured to pass through the channel 743 of the heating element and/or operatively interact with the element 70 for generating an aerosol. In addition, the biasing member 760 comprises an interacting portion 762 configured to pass through the opening 753 of the biasing member when the biasing member is located in the cavity 761 of the biasing member defined by the component body 750. In some aspects, a heating channel 763 of the biasing member may also be defined in the biasing member 760, configured to receive the second portion 745 of the heating element 737 therethrough. According to one aspect, as shown in Fig. 8B and 9B, the biasing member 760 may comprise a biasing portion 764 that is substantially cylindrical or tubular. In another aspect, as shown in Fig. 8C and 9C, the biasing member 760 may comprise a biasing portion 764 that comprises a plurality of teeth, projections, and/or the like that extend longitudinally from the first end of the biasing member 760 to the second end of the biasing member.

In some aspects, the biasing member 760 may be configured to provide a biasing force for biasing the aerosol generating element 70 outwardly from the heating cavity 740 when the end cap 780 is detached from the component housing 750. In one aspect, the consumer may push the biasing member 760 toward the aerosol generating element by gripping the engaging portion 762 and sliding the engaging portion 762 from the first end of the opening 753 of the biasing member toward the longitudinally opposite second end of the opening of the biasing member, as a result of which the biasing portion 764 operatively engages and/or pushes the aerosol generating element 70 out of the heating cavity 740.

According to another aspect, the biasing element may be operatively interacting with the wall element 741 and may be configured to apply a biasing force to the aerosol generating element 70 in a longitudinal direction outward from the heating cavity 740. For example, the biasing element may comprise a spring element and/or any suitable means for applying a biasing force to the aerosol generating element in the direction of the distal end 732 of the tubular body 730 and in a longitudinal direction outward from the heating cavity 740 when the end cap 780 is detached from the component body 750.

As mentioned earlier, the tubular body 730 may comprise a heating element 737 configured to supply heat to the heating cavity 740. In some aspects, the heating element 737 may be configured to supply heat to the heating cavity 740 when powered by a power source, such as, for example, a battery 755. In some aspects, the heating element 737 may comprise a resistive heating element, although other types of heating elements (i.e., induction, microwave, etc.) may also be implemented if necessary. According to some aspects, the heating element may comprise a coiled portion 38 and an elongated portion 39, as shown in Figs. 3A and 3B. In some aspects, the coiled portion 38 may be operatively connected to the elongated portion 39.

As shown in Fig. 9A-9C, the first or spiral-shaped portion 738 may be designed to extend in the longitudinal direction around the outer wall 734 generating the heating cavity 740. The second portion or portion 745 in the form of an elongated element may be designed to receive the channel 743 of the heating element, for example, by friction fit. In particular, the outer diameter of the second portion 745 may be smaller than the inner diameter of the channel 743 of the heating element. Thus, the channel 743 of the heating element may be designed to receive through it the second portion 745 of the heating element 737, as mentioned above. In some aspects, the second portion 745 may optionally comprise electrical wires (not shown) and/or corresponding electrical conductors for supplying electrical current from the battery 755 of the component housing 50 to the second portion 745 of the heating element 737. Additionally or alternatively, the second portion 745 may be configured to be electrically connected and/or communicate with the first portion 738 of the heating element 737 to provide an electrical connection and/or provide an electrical current flow between the battery 755 of the component housing 750 to the first portion of the heating element. In some aspects, the second portion 745 may optionally comprise electrical wires (not shown) and/or corresponding electrical conductors for supplying electrical current from the second portion 745 of the heating element 737 to the first portion 738 of the heating element located inside the tubular housing 730.

According to some aspects, the first portion 738 of the heating element 737 may comprise a helical or spiral-shaped portion configured to extend longitudinally around the outer wall 734 generating the heating cavity 740. Additionally or alternatively, the second portion 745 of the heating element 737 may comprise an elongated element portion configured to extend longitudinally, and wherein the elongated element portion may be configured to be received within a heating element channel 743 defined by a wall element 741 of the tubular body 730. Thus, the second portion 745 of the heating element 737 may be configured to extend longitudinally along a central axis about which the helical first portion 738 of the heating element 737 rotates. Thus, the heating element 737 may be configured to supply heat to the heating cavity 740 both laterally through the outer wall 734, and laterally through the second portion 745, when the second portion operatively interacts with the channel 743 of the heating element and is received by it. According to some aspects, the second portion 745 in the form of an elongated element of the heating element 737 may be formed not in the form of a rod-shaped element, but in another desired manner. For example, the second portion 745 in the form of an elongated element in some cases may be formed as a twisted into a spiral or helicoidal portion, as shown in Fig. 3B. Accordingly, one aspect of the present invention includes the heating element 737, comprising a first portion 738 formed in the form of a spiral, which rotates about an axis, and a second portion 745 in the form of an elongated element, which is formed as a twisted into a spiral or helicoidal portion, which also rotates about the same axis.

According to some aspects, the second portion 745 in the form of an elongated element may be located inside the housing, which may be formed in one piece with the tubular housing 730. Thus, the first portion 738 in the form of a spiral of the heating element 737 may be formed in one piece with the second portion 745 in the form of an elongated element, forming a single heating element 737. In another aspect, the first portion 738 in the form of a spiral and the second portion 745 in the form of an elongated element of the heating element 737 may be separate portions of the heating element, as shown in Figs. 9A-9C, which may also be configured to be separately controlled for supplying heat to the heating cavity 740. Thus, the first portion 738 in the form of a spiral may be activated for supplying heat to the heating cavity 740, while the second portion 745 in the form of an elongated element may remain in the off state. In an alternative embodiment, the second section 745 in the form of an elongated element 745 can be activated to supply heat to the heating cavity 740, while the first section 738 made in the form of a spiral can remain in the switched-off state. In addition, the first section 738 made in the form of a spiral can be controlled by a control unit to supply heat to the heating cavity 740 at a certain temperature, while the second section 745 in the form of an elongated element can be controlled by the same or another control unit to supply heat to the heating cavity at the same or another temperature.

Thus, aspects of the present invention preferably provide for significant and uniform heating of the aerosol-generating element by providing a plurality of heating elements or a heating element comprising a plurality of sections located inside the tubular body 730. In particular, a smoking article according to one aspect comprises a heating element 737 that comprises a first section 738 made in the form of a spiral, which is located near the outer wall 34, which provides heating for the outermost radial sections of the aerosol-generating element 70, while the second section 745 in the form of an elongated element provides heating for the radial sections of the aerosol-generating element closest to the central axis. Accordingly, the heating element 737 can preferably provide heating of the aerosol-generating element 70 in the radial direction inward from the outer wall 734 and simultaneously heating of the aerosol-generating element in the radial direction outward from the second section 745, even if the second section 745 is located in its own body.

In the manufacture of the smoking article, the aerosol generating element 70 is inserted into the heating cavity 740 to enable it to be heated by the heating element 737, as discussed earlier in this document. According to one aspect of the present invention, the aerosol generating element 70 may be solid tobacco particles and/or tobacco-related material that have a shape and configuration (i.e., a permanent hollow cylindrical shape) that ensures their reception in the heating cavity 740, as shown in Fig. 4A. In the case of using a permanent hollow cylindrical shape of the aerosol generating element 70, the aerosol generating element may be manufactured in a continuous process, such as, for example, an extrusion process. In another aspect, the heating cavity 40 can be formed by a substantially cylindrical body 745 of the second portion and a tapering cylindrical outer wall 734 so that the corresponding aerosol generating element 70 can have the shape of a tapering hollow cylinder. Thus, the surface 72 of the aerosol generating element 70, which interacts with the wall element 741, formed by the heating cavity 740 over the aerosol generating element inserted into the heating cavity 740, can have a smaller diameter than the opposite surface 71 of the aerosol generating element, as shown in Fig. 4B. Although such a tapering shape may facilitate the removal of the aerosol generating element from the heating cavity, an aerosol generating element having such a shape cannot be manufactured in a continuous process (i.e., by extrusion), and in this case the aerosol generating element can be manufactured in the form of separate blocks in a discrete process, such as, for example, molding or casting. In another aspect, at least a part of the body 745 of the second portion can be made in the form of a tapering cylinder, while the outer wall 734 can have a substantially cylindrical shape. Therefore, the corresponding element 70 for generating an aerosol can be formed in such a way that the surface 72 of the element 70 for generating an aerosol interacting with the element in the form of a wall has a smaller cross-sectional area than the cross-sectional area of the opposite surface 71 of the element 70 for generating an aerosol, as shown in Fig. 4C. In another aspect, both the outer wall 734 and at least a portion of the body 745 of the second portion may be tapered in opposite longitudinal directions such that the corresponding aerosol generating element shown in Fig. 4D comprises a surface 72 having a smaller cross-sectional area than the cross-sectional area of the opposite surface 71 of the aerosol generating element 70. In addition, the surface 72 may have a smaller diameter than the opposite surface 71. Accordingly, when the aerosol generating element 70 of the corresponding shape is inserted into the heating cavity formed by the tapered outer wall 734 and the second portion 745 of the housing in opposite longitudinal directions, the tapered shape of the outer wall and the second portion of the housing facilitates the removal of the aerosol generating element 70 from the heating cavity 740, since the opposite tapered inner and outer walls provide minimal resistance and/or contact with the aerosol generating element when the aerosol generating element is removed from the heating cavity. Although the ones shown in Fig. 4A-4D illustrate various shapes of the aerosol generating elements, typically in the form of hollow cylinders, the present invention also includes other shapes such as, for example, a hollow cuboid, a hollow parallelepiped, and/or the like. In addition, the aerosol generating material 70 may contain solid tobacco particles and/or a tobacco-related material and may be molded and/or formed into a hollow cylindrical extrudate as shown in Fig. 4A containing solid materials such as tobacco, a tobacco component, or a tobacco-derived material (i.e., a material that is naturally present in tobacco and that can be directly isolated from tobacco or synthetically prepared), as discussed previously herein.

According to some aspects, the original aerosol generating element 70 may include an identifying component configured to identify the aerosol generating element as an original and genuine aerosol generating element. For example, in one aspect, the identifying component may include a specially shaped element formed on the aerosol generating element in such a way that the insertion of the aerosol generating element into the heating cavity 740 can be performed and completed only when the aerosol generating element with the specially shaped element is inserted into the heating cavity 740. For example, the surface 72 of the aerosol generating element 70 may have a recess located at a certain location. In addition, the wall element 741 defining the heating cavity 740 may include a corresponding protrusion that is configured to interact, mate and/or operatively connect with the recess on the surface 72 of the aerosol generating element. Thus, only the original aerosol generating elements comprising an authenticating element of a certain shape can be fully inserted inside the heating cavity. According to another aspect, the outer wall 734 and/or the second section 745 of the housing can form a protrusion which extends in the longitudinal direction from the wall element 741 to the opposite end of the hollow cylinder. Thus, the original aerosol generating element 70 can comprise a corresponding channel formed by the outer surface 74 and/or the inner surface 75, configured to ensure interaction, coupling and/or functional connection of the original aerosol generating element with the longitudinal protrusion formed on the outer wall 734 and/or the second section 745 of the housing forming the heating cavity. Thus, any formed distinctive features, elements, protrusions, channels and/or the like of the aerosol generating element can act as an authenticating means for the smoking article in the aspect that only an original and suitably shaped aerosol generating element can be used with the smoking article according to the present invention. For example, longitudinally extending projections formed on the outer wall 734 and/or the second portion 745 of the housing, a projection extending from the wall element 741, and/or a physical element of any other suitable shape may be configured to cooperate with a control unit configured to be activated in response to a functional interaction between the suitably shaped physical element and the correspondingly shaped element and/or portion of the aerosol generating element such that the control unit can activate the power source with the heating element only when the suitably shaped physical element is in functional interaction with the correspondingly shaped element and/or portion of the aerosol generating element. In some aspects, the aerosol generating element 70 may further comprise an identifying component configured to electronically cooperate with any of the control units of the smoking article to authenticate the aerosol generating element as a genuine and original aerosol generating element, as discussed earlier in this document.

According to one aspect, the present invention may also be related to corresponding methods, such as, for example, a method for manufacturing an electronic smoking article. Such a method may include introducing a power source, such as, for example, a battery 755, into a component housing 750 defining a cavity 759 of the power source, as shown in Fig. 9A-9C, wherein the component housing has a first end and a longitudinally opposite second end. The component housing may have an end cooperating with a mouthpiece or a first end and an end cooperating with a tubular housing or a second end opposite in the longitudinal direction. In some aspects, the first or second end may be an end cooperating with a mouthpiece. In another aspect, the first or second end may be an end cooperating with a tubular housing. In addition, the end of the component housing cooperating with a tubular housing may also be configured to operatively interact with an end cap. The component body may further comprise at least one internal channel configured to connect and/or communicate via fluid medium with at least one of the mouthpiece channels, wherein the internal channel is formed by an element in the form of a wall of a tubular body, a heating cavity and/or at least one opening formed by an end cap.

The method may also include interacting the heating element with the tubular body. For example, the method may include interacting the second portion of the heating element with the tubular body in such a way that the first portion of the heating element extends around the outer wall (for example, the outer wall 734), and the second portion (for example, the second portion 745) extends through the central channel (for example, the channel 743 of the heating element) and in the cylindrical cavity (for example, the heating cavity 740) of the tubular body. The central channel may be located near the first end of the tubular body. In some aspects, the tubular body may have a first end and a second end opposite in the longitudinal direction. In addition, or as an alternative, the tubular body may comprise an outer wall extending in the longitudinal direction between them. According to some aspects, the first end of the tubular body may be configured to operatively interact the first or second end with the component body. In some aspects, the outer wall of the tubular body and the body of the second portion, which includes the second portion of the heating element, may form a hollow cylindrical cavity extending in the longitudinal direction between them.

According to some aspects, the method may further include interaction of the first end of the tubular body with the first or second end of the component body. In some aspects, the tubular body may have an end interacting with the component body and a longitudinally opposite distal end. According to one aspect, the end of the tubular body interacting with the component body may be the first end of the tubular body, and the longitudinally opposite distal end of the tubular body may be the second end of the tubular body. According to some aspects, the end of the tubular body interacting with the component body may be configured to operatively interact with the end of the component body interacting with the tubular body. In some aspects, the component body may comprise first, second and third interaction elements located on the inner surface of the component body. The second interaction element of the component housing, located near the end interacting with the tubular housing, can be configured to interact and/or functionally connect the component housing with the tubular housing by means of a mating interaction element located near the end of the tubular housing interacting with the component housing. According to some aspects, the second interaction element of the component housing can comprise a threaded surface configured to interact with the mating interaction element of the tubular housing, which can also comprise a threaded surface.

In addition, the method may include introducing an aerosol generating element into a hollow cylindrical cavity. The aerosol generating element may be configured to generate an aerosol from it upon heating, provided thereon by a heating element. According to some aspects, the heating element with the first and second portions may be configured to supply heat to the heating cavity, as a result of which an aerosol is formed from the aerosol generating element. In particular, the first portion of the heating element in the tubular body and the second portion of the heating element, which may be configured to be introduced into the channel of the heating element formed by the tubular body, may be configured to supply heat to the hollow cylindrical cavity, as described above in this document.

In other aspects, the aerosol generating element may be formed as a hollow cylinder, which is configured to be placed in a hollow cylindrical cavity. In addition, or as an alternative, the aerosol generating element may be formed as a hollow cylindrical extrudate of tobacco and/or tobacco-related material. In some aspects, the aerosol generating element may comprise an identifying component configured to identify the aerosol generating element as the original. Thus, according to some aspects of the present invention, the method may further include operatively engaging a conductive element associated with the identifying component with a circuit associated with the control unit. Accordingly, engaging the aerosol generating element in the hollow cylindrical cavity (i.e., the heating cavity 740) may result in activation of the control unit, which may be configured to be activated in response to the operative interaction between the conductive element of the identifying component and the circuit, if the aerosol generating element is the original. In some aspects, the control unit may be configured to provide functional interaction of the power source with the heating element, and the heating element may be configured to supply heat to the aerosol generating element when the conductive element is functionally interacted with the circuit.

According to another aspect, the method may further include functional interaction of the actuator with a power source. The power source may be configured to respond to the activation of the actuator by supplying power to the heating element, which may be configured to supply heat to the aerosol generating element.

According to some aspects, the aerosol-generating element may comprise an identifying component configured to identify the aerosol-generating element as the original. For example, the aerosol-generating element may further comprise a first physical element that is associated with the identifying component. The second physical element configured to be coupled may be capable of communicating with the control unit. Thus, the method may include activating the control unit when the aerosol-generating element is introduced into the hollow cylindrical cavity, and, in particular, when the first physical element is operatively interacting with the second physical element configured to be coupled. According to some aspects, the control unit may be configured to provide operative interaction of the power source with the heating element, wherein the heating element is configured to supply heat to the aerosol-generating element when the first physical element operatively interacts with the second physical element configured to be coupled.

In some aspects, the method may further include interaction of the heating element with the tubular body. The first portion of the heating element may be configured to pass around the outer wall of the tubular body. In some aspects, the second portion of the heating element may be configured to pass inside the body of the second portion, which may be configured to be received by the tubular body and to operatively interact with it. In addition, the first and second portions of the heating element may be configured to interact, communicate with a power source and/or engage the power source to supply heat to the aerosol generating element.

According to another aspect, the method may further include interacting the heating element with the tubular body in such a way that the helical portion of the heating element extends in the longitudinal direction along the outer wall. For example, the first portion of the heating element may be a helical portion extending in the longitudinal direction along the outer wall of the tubular body. In some aspects, the method may include interacting the heating element with the tubular body in such a way that the portion in the form of an elongated element of the heating element (for example, the second portion of the heating element) extends in the longitudinal direction and concentrically through a central channel, such as, for example, a channel of the heating element formed by the element in the form of a wall. The channel of the heating element may be located concentrically relative to the outer wall of the tubular body. Thus, the second portion in the form of an elongated element of the heating element may be configured to extend in the longitudinal direction and concentrically through the central channel and to extend into a cylindrical cavity formed by the tubular body. In another aspect, the second portion of the heating element may include a spiral-shaped portion that extends longitudinally and concentrically through the central channel and extends into a cylindrical cavity formed by the tubular body.

As mentioned earlier, the component body may include at least one internal channel which extends in the longitudinal direction from the first end to the second end of the component body. The internal channel formed in the component body may be configured to provide a connection and/or fluid communication between at least one opening and/or internal channel formed in the tubular body and a mouthpiece channel formed in the mouthpiece section. The mouthpiece channel may extend in the longitudinal direction from one end of the mouthpiece section to the opposite second end in the longitudinal direction. In addition, or as an alternative, the method may further include a functional interaction of one end in the longitudinal direction of the mouthpiece section with the first or second end of the component body opposite the other of the first and second ends of the component body interacting with the tubular body. For example, the end of the mouthpiece portion interacting with the component housing may be configured to operatively interact with the end of the component housing interacting with the mouthpiece, wherein the end of the component housing interacting with the mouthpiece is located oppositely in the longitudinal direction relative to the end of the component housing interacting with the tubular housing. In some aspects, the method may include operatively interacting the end of the mouthpiece portion interacting with the end of the component housing interacting with the mouthpiece in such a way that the conductive element associated with the mouthpiece portion interacts with the first portion of the heating element associated with the tubular housing and/or the second portion of the heating element that extends inside the cylindrical cavity to form a heating element circuit when the mouthpiece portion and the component housing operatively interact. In another aspect, the conductive element associated with the mouthpiece portion may be configured to interact with a first portion of the heating element associated with the tubular body and/or a second portion of the heating element configured to extend into the cylindrical cavity to form a heating element circuit when the mouthpiece portion operatively interacts with the component body and the tubular body operatively interacts with the component body.

Many modifications and other embodiments of the present invention set forth in this application may be apparent to those skilled in the art upon review of the above descriptions and accompanying drawings. It is therefore to be understood that the present invention is not limited to the specific embodiments described herein, and that modifications and other embodiments are within the scope of protection of the present invention as defined by the appended claims. Although specific terms are used in this application, they are used in a general and descriptive sense only and not for purposes of limitation.

Claims (33)

1. A smoking product containing: a component housing containing a power source; a reusable mouthpiece having a first end and a second end opposite in the longitudinal direction with an internal channel passing between them in the longitudinal direction, wherein the first end is configured to interact with the user's mouth; a housing having a first end and a second end opposite in the longitudinal direction, wherein the first end is configured to accommodate a component housing, and the second end is configured to accommodate a reusable mouthpiece, wherein the housing comprises an outer wall forming an internal cavity inside said housing; and a heating element comprising a first section located around the inner surface of the outer wall of said housing, and a second section comprising an elongated element extending along the longitudinal axis of the inner cavity of said housing, wherein the first and second sections of the heating element functionally interact with the power source and are designed with the possibility of selectively operating by means of it to supply heat. 2. A smoking article according to item 1, also comprising an aerosol generating element forming an outer surface and an inner surface, wherein the aerosol generating element is configured to be placed entirely within the internal cavity of the housing, so that when it is placed within the internal cavity, the outer surface of the aerosol generating element interacts with the first section of the heating element, and the inner surface of the aerosol generating element interacts with the second section of the heating element, wherein the aerosol generating element is configured to be selectively heated by the first and second sections of the heating element to generate an aerosol. 3. A smoking article according to claim 1, wherein the internal channel of the mouthpiece is designed to communicate via a fluid medium with the internal cavity of the body. 4. A smoking article according to item 1, in which the mouthpiece is detachably connected to the body. 5. A smoking article according to claim 1, wherein the mouthpiece is permanently connected to the body. 6. A smoking article according to claim 1, wherein the mouthpiece is connected to the body by means of at least one of the following: mating threaded surfaces for screw interaction, clamping interaction, snap interaction or magnetic interaction. 7. A smoking article according to claim 1, wherein the mouthpiece comprises a control component and is operatively connected to the component body. 8. A smoking article according to claim 7, wherein the control component comprises a sensor. 9. The smoking article according to claim 8, wherein the sensor comprises at least one of the following: a flow sensor, a pressure sensor or a capacitive sensor. 10. A smoking article according to claim 1, wherein the mouthpiece comprises a conductive element that provides functional interaction between the mouthpiece and the housing or component housing, and the conductive element is configured to interact with the heating element to form a heating element circuit. 11. The smoking article according to claim 2, also comprising an actuator, wherein the power source is configured to respond to the activation of the actuator by selectively supplying power to at least one of the first section or the second section of the heating element for selectively heating the aerosol generating element. 12. A smoking article according to claim 2, wherein the aerosol generating element comprises an identifying component configured to identify the aerosol generating element as the original. 13. A smoking article according to claim 12, wherein the identifying component comprises a first physical element located on the aerosol-generating element and configured to functionally interact with a second physical element configured to be coupled, located inside the internal cavity and communicating with the control unit, wherein when the aerosol-generating element is placed inside the internal cavity, the control unit is configured to activate it in response to the functional interaction between the first and second physical elements configured to be coupled. 14. A smoking article according to claim 13, wherein the first physical element comprises a recess on the surface of the aerosol generating element, and the second physical element comprises a projection configured to be operatively connected to the recess formed by the surface of the aerosol generating element. 15. A smoking article according to claim 12, wherein the identifying component comprises a conductive element configured to functionally interact with a circuit associated with a control unit when the aerosol generating element is placed inside the internal cavity, wherein the control unit is configured to be activated in response to a functional interaction between said conductive element and said circuit. 16. A smoking article according to claim 2, wherein the aerosol generating element is at least partially hollow, such that the inner and outer surfaces are coaxially aligned around the longitudinal axis of the aerosol generating element, and the second portion of the heating element is at least partially located within the hollow inner surface. 17. A smoking article according to claim 2, wherein the aerosol generating element comprises an extruded substrate. 18. A smoking article according to claim 2, wherein the aerosol generating element is a hollow extrudate of a tobacco-related material corresponding to the internal cavity and configured to be placed in the internal cavity. 19. A smoking article according to claim 2, also comprising a biasing element at least partially located in the internal cavity and configured to functionally interact with the aerosol generating element. 20. A smoking article according to claim 19, wherein the biasing element is designed to push the aerosol generating element outward from the internal cavity. 21. A smoking article according to claim 19, wherein the second end of the reusable mouthpiece is configured to pass inside the housing, so that the mouthpiece interacts with the aerosol generating element to push the aerosol generating element close to the biasing element and into the heating cavity inside the inner cavity. 22. A smoking article according to claim 19, wherein the second end of the reusable mouthpiece is designed to pass inside the housing so that the mouthpiece interacts with the aerosol generating element to push the aerosol generating element close to the biasing element and bring it into contact with the heating element. 23. A smoking article according to claim 1, wherein the first section of the heating element comprises a helicoidal section extending around the outer wall and in the longitudinal direction along it. 24. A smoking article according to claim 1, wherein the first section of the heating element comprises a helicoidal section extending around the outer wall and in the longitudinal direction along it, and the elongated element of the second section of the heating element extends near the helicoidal section and in the longitudinal direction along the inner wall. 25. A smoking article according to claim 1, wherein the elongated element of the second section of the heating element comprises a helicoidal section extending in the longitudinal direction within the internal cavity. 26. A smoking article according to claim 1, wherein the outer wall forming the internal cavity contains a heat-conducting material. 27. The smoking article according to claim 2, also comprising a control unit configured to provide functional interaction of the power source with at least one of the first section or the second section of the heating element, wherein the first section and the second section of the heating element are configured to selectively supply heat to the aerosol generating element in response to the functional interaction between the mouthpiece and the control unit.