JP7756645B2 - Smoking articles with downstream flavoring - Google Patents

Description

This application claims priority to and the benefit of U.S. Patent Application No. 16/732,747, entitled "Smoking Article with Downstream Flavor Addition," filed January 2, 2020, the entire contents of which are incorporated herein by reference.

The present disclosure relates to aerosol delivery devices and systems, e.g., smoking articles, and more particularly to aerosol delivery devices and systems (e.g., smoking articles for obtaining tobacco and other material components in an inhalable form, commonly referred to as heat-burning systems or e-cigarettes) that utilize a heat source, such as a combustible carbon-based ignition source, configured to generate heat for the generation of an aerosol. The components of such articles may be made from or derived from tobacco, or these articles may otherwise feature tobacco incorporated for human consumption, and may be capable of vaporizing the tobacco and/or other tobacco-related material components to form an inhalable aerosol for human consumption.

Many smoking articles have been proposed over the years as improvements or replacements for smoking products based on tobacco combustion. Exemplary alternatives include devices in which a solid or liquid fuel is combusted to transfer heat to the tobacco, or devices in which a chemical reaction is used to provide such a heat source. Examples include the smoking articles described in U.S. Pat. No. 9,078,473 to Worm et al., which is incorporated herein by reference.

A key focus for improvements or replacements to smoking articles has typically been to provide the sensations associated with smoking a cigarette, cigar, or pipe without delivering significant amounts of incomplete combustion and pyrolysis products. To this end, many smoking products, flavor generators, and medicated inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials or attempt to provide the sensations of smoking a cigarette, cigar, or pipe without significantly burning tobacco. See, for example, U.S. Pat. No. 7,726,320 to Robinson et al. and the various alternative smoking articles, aerosol delivery devices, and heat sources described in the background art of U.S. Patent Application Publication Nos. 2013/0255702 to Griffith, Jr. et al. and 2014/0096781 to Sears et al., which are incorporated herein by reference. See also, for example, the various types of smoking articles, aerosol delivery devices, and electrically powered heating sources referenced by trade names and commercial sources described in U.S. Patent Application Publication No. 2015/0220232 to Bless et al., which is incorporated herein by reference. Additional types of smoking articles, aerosol delivery devices, and electrically powered heating sources referenced by trade names and commercial sources are described in U.S. Patent Application Publication No. 2015/0245659 to DePiano et al., which is also incorporated herein by reference in its entirety. Other representative cigarettes or smoking articles that have been described, and in some cases are commercially available, include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al., U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,249,586 to Counts et al., U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,060,671 to Counts ... Counts et al., U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,249,586 to Counts et al., U. No. 5,388,594, U.S. Pat. No. 5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513, No. 253 to Robinson et al., U.S. Pat. No. 7,726,320 to Hamano, U.S. Pat. No. 7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. Appl. Pub. Nos. 2009/0095311 to Hon, U.S. Pat. Appl. Pub. Nos. 2006/0196518 to Hon, U.S. Pat. Appl. Pub. Nos. 2009/0126745 and 2009/0188490 to Thorens et al. These include those described in U.S. Patent Application Publication No. 2009/0272379, U.S. Patent Application Publication Nos. 2009/0260641 and 2009/0260642 to Monsees et al., U.S. Patent Application Publication Nos. 2008/0149118 and 2010/0024834 to Oglesby et al., U.S. Patent Application Publication No. 2010/0307518 to Wang, and International Publication No. 2010/091593 to Hon.

Various styles and methods have been proposed for assembling smoking articles having multiple sequentially arranged segmented components. See, for example, the various types of assembly techniques and methods described in U.S. Pat. Nos. 5,469,871 to Barnes et al. and 7,647,932 to Crooks et al., as well as U.S. Patent Application Publication Nos. 2010/0186757 to Crooks et al., 2012/0042885 to Stone et al., and 2012/00673620 to Conner et al., each of which is incorporated herein by reference in its entirety.

Representative products that mimic many of the attributes of traditional cigarettes, cigars, or pipes include 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 Fontem Ventures B.V., and EPUFFER® International Inc. COHITA™, COLIBRI™, ELITE CLASSIC™, MAGNUM™, PHANTOM™, and SENSE™ manufactured by Electronic Cigarettes, 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 Elution UK Ltd; EONSMOKE® manufactured by Eonsmoke LLC; FIN™ manufactured by FIN Branding Group, LLC; SMOKE® manufactured by Greenarette LLC, 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, and Luciano Smokes Inc. LUCI® manufactured by Nicotek, LLC, 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, and Ruyan Group (Holdings) Ltd. RUYAN® manufactured by Smoker Friendly International, LLC, 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, and Vapor 4 Life, Inc. These are commercially available as VAPOR4LIFE® from E-CigaretteDirect, LLC, VEPPO™ from E-CigaretteDirect, LLC, VUSE® from R. J. Reynolds Vapor Company, Mystic Menthol products from Mystic Ecigs, and Vype products from CN Creative Ltd., IQOS™ from Philip Morris International, and GLO™ from British American Tobacco. Still other electrically powered aerosol delivery devices, particularly those characterized as so-called electronic cigarettes, are commercially available under the trade names COOLER VISIONS™, DIRECT E-CIG™, DRAGONFLY™, EMIST™, EVERSMOKE™, GAMUCCI®, HYBRID FLAME™, KNIGHT STICKS™, ROYAL BLUES™, SMOKETIP®, and SOUTH BEACH SMOKE™.

U.S. Pat. No. 9,078,473 U.S. Patent No. 7,726,320 US Patent Application Publication No. 2013/0255702 US Patent Application Publication No. 2014/0096781 US Patent Application Publication No. 2015/0220232 US Patent Application Publication No. 2015/0245659 U.S. Pat. No. 4,735,217 U.S. Pat. No. 4,922,901 U.S. Pat. No. 4,947,874 U.S. Pat. No. 4,947,875 U.S. Pat. No. 5,060,671 U.S. Pat. No. 5,249,586 U.S. Patent No. 5,388,594 U.S. Pat. No. 5,666,977 U.S. Patent No. 6,053,176 U.S. Patent No. 6,164,287 U.S. Patent No. 6,196,218 U.S. Patent No. 6,810,883 U.S. Patent No. 6,854,461 U.S. Patent No. 7,832,410 U.S. Patent No. 7,513,253 U.S. Patent No. 7,896,006 U.S. Patent No. 6,772,756 US Patent Application Publication No. 2009/0095311 US Patent Application Publication No. 2006/0196518 US Patent Application Publication No. 2009/0126745 US Patent Application Publication No. 2009/0188490 US Patent Application Publication No. 2009/0272379 US Patent Application Publication No. 2009/0260641 US Patent Application Publication No. 2009/0260642 US Patent Application Publication No. 2008/0149118 US Patent Application Publication No. 2010/0024834 US Patent Application Publication No. 2010/0307518 International Publication No. 2010/091593 U.S. Pat. No. 5,469,871 U.S. Patent No. 7,647,932 US Patent Application Publication No. 2010/0186757 US Patent Application Publication No. 2012/0042885 US Patent Application Publication No. 2012/00673620

Conventional smoking articles, such as those referenced above, can be difficult to assemble as a result of multiple components that must be disassembled and reassembled upon ingestion of the aerosol delivery components provided therein. In yet another example, conventional smoking articles can suffer from poor performance with respect to aerosolizing aerosol-forming components. It would be desirable to provide smoking articles with improved functionality. In this regard, it would be desirable to provide smoking articles with advantageous features.

In various implementations, the present disclosure provides smoking articles. The present disclosure includes, but is not limited to, the following exemplary implementations:

Exemplary Implementation 1: A smoking article comprising at least one substrate material portion having an aerosol precursor composition bound thereto, a flavoring component, and a mouthpiece disposed downstream of the heat source and the at least one substrate material portion, the mouthpiece including a filter, the mouthpiece including a flavoring component containing a plurality of flavor beads adjacent to a hollow flow tube, the flow tube including a plurality of peripheral openings defined therethrough.

Exemplary Implementation 2: The smoking article of exemplary implementation 1, or any combination of any of the preceding exemplary implementations, further comprising a combustible heat source, the combustible heat source being positioned in proximity to at least a portion of at least one substrate material portion.

Exemplary Implementation 3: A smoking article of any of exemplary implementations 1-2, or any combination of any of the preceding exemplary implementations, further comprising a device separate from the smoking article, the separate device including an electric heat source configured to heat at least a portion of at least one substrate material portion.

Exemplary Implementation 4: A smoking article of any of exemplary implementations 1-3, or any combination of any of the preceding exemplary implementations, wherein the flavoring component is positioned downstream of the filter.

Exemplary Implementation 5: A smoking article of any of exemplary implementations 1-4, or any combination of any of the preceding exemplary implementations, wherein the multiple peripheral openings of the flow tube comprise multiple holes penetrating the peripheral wall of the flow tube.

Exemplary Implementation 6: A smoking article of any of exemplary implementations 1-5, or any combination of any of the preceding exemplary implementations, wherein the multiple peripheral openings of the flow tube comprise multiple slots that penetrate the peripheral wall of the flow tube.

Exemplary Implementation 7: A smoking article of any of exemplary implementations 1-6, or any combination of any of the preceding exemplary implementations, wherein the flow tube extends through at least a portion of the filter.

Exemplary Implementation 8: The smoking article of any of exemplary implementations 1-7, or any combination of any of the preceding exemplary implementations, wherein the plurality of flavor beads comprises at least one of tobacco flavor beads, non-tobacco flavor beads, gel flavor beads, capsules containing flavor beads, or any combination thereof.

Exemplary Implementation 9: A smoking article of any of exemplary implementations 1-8, or any combination of any of the preceding exemplary implementations, wherein the filter defines a cavity, the plurality of flavor beads are disposed within the cavity, and the flow tube extends through at least a portion of the filter.

Exemplary Implementation 10: A smoking article of any of exemplary implementations 1-9, or any combination of any of the foregoing exemplary implementations, further comprising a second substrate material disposed between the first substrate material and the mouthpiece.

Exemplary Implementation 11: A smoking article of any of exemplary implementations 1-10, or any combination of any of the foregoing exemplary implementations, wherein the substrate material contains at least one of tobacco-containing beads, tobacco shreds, tobacco strips, reconstituted tobacco material pieces, or tobacco rods.

Exemplary Implementation 12: A smoking article comprising at least one substrate material portion having an aerosol precursor composition bound thereto, a flavor-imparting component, and a mouthpiece disposed downstream of the heat source and the at least one substrate material portion, the mouthpiece including a filter, wherein the mouthpiece includes the flavor-imparting component, the filter defines a cavity therein, the flavor-imparting component contains a plurality of flavor beads, and the plurality of flavor beads are disposed within the cavity.

Exemplary Implementation 13: A smoking article of exemplary implementation 12, or any combination of any of the preceding exemplary implementations, further comprising a heat source, the heat source being positioned in proximity to at least a portion of at least one substrate material portion.

Exemplary Implementation 14: The smoking article of any of exemplary implementations 12-13, or any combination of any of the preceding exemplary implementations, further comprising a device separate from the smoking article, the separate device including an electric heat source configured to heat at least a portion of at least one substrate material portion.

Exemplary Implementation 15: A smoking article of any of exemplary implementations 12-14, or any combination of any of the foregoing exemplary implementations, further comprising a hollow flow tube, the flow tube extending through at least a portion of the filter.

Exemplary Implementation 16: A smoking article of any of exemplary implementations 12-15, or any combination of any of the preceding exemplary implementations, wherein the plurality of flavor beads substantially surrounds the flow tube.

Exemplary Implementation 17: A smoking article of any of exemplary implementations 12-16, or any combination of any of the foregoing exemplary implementations, wherein the flow tube includes a plurality of peripheral openings defined therethrough.

Exemplary Implementation 18: A smoking article of any of exemplary implementations 12-17, or any combination of any of the foregoing exemplary implementations, wherein the multiple peripheral openings of the flow tube comprise multiple holes penetrating the peripheral wall of the flow tube.

Exemplary Implementation 19: A smoking article of any of exemplary implementations 12-18, or any combination of any of the foregoing exemplary implementations, wherein the multiple peripheral openings of the flow tube comprise multiple slots that penetrate the peripheral wall of the flow tube.

Exemplary Implementation 20: The smoking article of any of exemplary implementations 12-19, or any combination of any of the foregoing exemplary implementations, wherein the plurality of flavor beads comprises at least one of tobacco flavor beads, non-tobacco flavor beads, gel flavor beads, capsules containing flavor beads, or any combination thereof.

Exemplary implementation 21: A smoking article of any of exemplary implementations 12-20, or any combination of any of the foregoing exemplary implementations, further comprising a second substrate material disposed between the first substrate material and the mouthpiece.

Exemplary Implementation 22: A smoking article of any of exemplary implementations 12-21, or any combination of any of the foregoing exemplary implementations, wherein the substrate material contains at least one of tobacco-containing beads, tobacco shreds, tobacco strips, reconstituted tobacco material pieces, or tobacco rods.

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

The present disclosure having been described in general terms above, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale.

1 shows a perspective view of a smoking article according to one implementation of the present disclosure. 2 shows a perspective view of the smoking article of FIG. 1 with the outer wrap removed, according to one implementation of the present disclosure. 1 shows a schematic longitudinal view of a smoking article according to one implementation of the present disclosure. 1 shows a schematic longitudinal view of a smoking article according to one implementation of the present disclosure. 1 shows a schematic longitudinal view of a smoking article according to one implementation of the present disclosure. 1 shows a schematic longitudinal view of a smoking article according to one implementation of the present disclosure. 1 shows a schematic longitudinal view of a smoking article according to one implementation of the present disclosure. 1 shows a schematic longitudinal view of a smoking article according to one implementation of the present disclosure.

The present disclosure will now be described in more detail with reference to exemplary embodiments thereof. These exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

This disclosure provides a description of articles (and their assembly and/or manufacture) in which a material is heated (preferably without significant combustion of the material) to form an aerosol and/or inhalable substance. Most preferably, such articles are small enough to be considered "handheld" devices. In some aspects, the articles are characterized as smoking articles. As used herein, the term "smoking article" is intended to mean an article and/or device that provides many of the sensations of smoking a cigarette, cigar, or pipe (e.g., the inhalation and exhalation pattern, the type of taste or flavor, the sensory stimulating effect, the physical feel, the mode of use, the visual stimuli such as those provided by a visible aerosol, etc.) without substantially combusting any of the components of the article and/or device. As used herein, the term "smoking article" does not necessarily mean that, during operation, the article or device produces smoke in the sense of an aerosol resulting from the by-products of tobacco combustion or pyrolysis, but rather that the article or device produces vapor (including vapor within an aerosol that is considered a visible aerosol, which may be considered to be described as smoky) due to the volatilization or vaporization of certain components, elements, etc. of the article and/or device. In some aspects, articles or devices characterized as smoking articles incorporate tobacco and/or tobacco-derived components.

As previously mentioned, the aerosol-generating components of certain aerosol delivery devices may provide many of the sensations (e.g., inhalation and exhalation patterns, types of tastes or flavors, sensory stimulating effects, physical sensations, modes of use, visual cues such as those provided by visible aerosol, etc.) of smoking a cigarette, cigar, or pipe used by lighting and burning tobacco (and thus inhaling tobacco smoke) without substantially burning any of its components. For example, a user of an aerosol delivery device according to some exemplary implementations of the present disclosure may hold and use the components, draw on one end of the component to inhale the aerosol generated by the component, take puffs at selected time intervals, etc., in the same manner as a smoker uses a conventional smoking article.

The articles or devices of the present disclosure may also be characterized as being vapor-producing articles, aerosol delivery articles, or drug delivery articles. Accordingly, such articles or devices may be configured to provide one or more substances in an inhalable form or state. For example, the inhalable substance may be substantially in vapor form (e.g., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance may be in aerosol form (e.g., a suspension of fine solid particles or liquid droplets in a gas). For clarity, the term "aerosol" as used herein is meant to include vapors, gases, and aerosols in any form or type suitable for human inhalation, regardless of whether they are visible or in a form that may be considered smoky. In some implementations, the terms "vapor" and "aerosol" may be interchangeable. Therefore, for simplicity, the terms "vapor" and "aerosol" used to describe the present disclosure are understood to be interchangeable unless otherwise specified.

When used, smoking articles of the present disclosure are subject to many of the physical actions of an individual using a conventional smoking article (e.g., a cigarette, cigar, or pipe that is used by lighting it with a flame and then inhaling the burned and/or combusted tobacco). For example, a user of a smoking article of the present disclosure holds the article as with a conventional smoking article, draws on one end of the article to inhale the aerosol produced by the article, and takes puffs for selected time intervals.

While the systems are generally described herein with respect to implementations related to smoking articles, such as so-called "tobacco heating products," it should be understood that the features, components, features, and methods may be embodied in many different forms and associated with a variety of items. For example, the descriptions provided herein may be used in conjunction with implementations of traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heated tobacco products, and related packaging for any of the products disclosed herein. Accordingly, it should be understood that the descriptions of the features, components, features, and methods disclosed herein are discussed by way of example only with respect to implementations related to aerosol delivery devices, and may be embodied in and used in a variety of other products and methods.

Smoking articles of the present disclosure generally include numerous elements disposed or housed within some type of enclosure, such as a housing, outer wrap or packaging, casing, component, module, or member. The overall design of the enclosure varies, as does the type or configuration of the enclosure that defines the overall size and shape of the smoking article. In some, but not all, implementations, the overall design, size, and/or shape of the enclosure resembles that of a traditional cigarette or cigar. In various aspects, the heat source may generate heat to aerosolize, for example, extruded structures and/or substrates in solid or liquid form (e.g., beads, sheets, shreds, wraps), substrate materials combined with an aerosol precursor composition, substrate materials comprising tobacco and/or tobacco-related materials, such as materials directly isolated from tobacco, materials naturally found in tobacco, or synthetically prepared materials. In some implementations, the extruded structure may contain a tobacco product or a composite of tobacco and other materials, such as ceramic powder. In other implementations, porous ceramic beads may be loaded with a tobacco extract/slurry. Other implementations may use non-tobacco products. In some implementations, porous beads/powder (ceramic) loaded with the aerosol precursor composition may be used. In other implementations, rods/cylinders made from an extruded slurry of ceramic powder and the aerosol precursor composition may be used.

Smoking articles according to the present disclosure may take on a variety of implementations, as described in detail below, although the use of the smoking article by a consumer will be similar in scope. The above description of the use of a smoking article is applicable to the various implementations described, with minor modifications that will be apparent to those skilled in the art in light of the further disclosure provided herein. However, the description of use is not intended to limit the use of the article of the present invention, but is provided to fulfill all necessary requirements of the disclosure herein.

According to certain aspects of the present disclosure, it may be advantageous to provide a smoking article that provides downstream flavoring. FIGS. 1-5 show exemplary implementations of such a smoking article. In particular, FIG. 1 shows a perspective view of a smoking article 100 including an outer wrap 102, and FIG. 2 shows the smoking article 100 with the outer wrap 102 removed to expose the other components of the smoking article 100. Referring to FIG. 2, the smoking article of the illustrated implementation includes a heat source 104, a first substrate material 106, a second substrate material 108, a filter 110, and a downstream flavoring component 112. As will be described in more detail with respect to other exemplary implementations, the downstream flavoring component may have a variety of different configurations. In the illustrated implementation, the filter 110 and the flavoring component 112 together comprise a mouthpiece 114.

In various implementations, the filter may comprise a disk or other device positioned radially and/or longitudinally adjacent the downstream end of the smoking device. In this manner, upon drawing on the mouthpiece, the filter can receive aerosol flowing through the device. In some implementations, the filter may comprise individual segments. In some implementations, the filter may be constructed from a filler rod or cylindrical disk constructed from a gas-permeable material (e.g., cellulose acetate, or fibers such as paper or rayon, or polyester fibers, etc.). In some implementations, the filter may comprise cellulose acetate tow, gathered polypropylene web, cellulose acetate tubing, polylactic acid (PLA) filter material, etc. In some implementations, the filter may additionally or alternatively comprise strands of tobacco-containing material, as described in U.S. Pat. No. 5,025,814 to Raker et al., incorporated herein by reference in its entirety. In some implementations, the filter may include segments that provide filtration, segments that provide resistance to withdrawal, hollow segments that provide space for aerosol to cool, other filter segments, and any one or any combination of the above. In some implementations, the filter may include one or more filter segments, which may be replaceable.

In the illustrated implementation, the first and second substrate materials 106, 108 may have a longitudinally extending axis defined centrally between each of their respective opposing first and second ends, and the cross-sections of the first and second substrate materials 106, 108 may be symmetrical about the axis in some implementations. For example, in some implementations, the cross-sections of the first and second substrate materials 106, 108 may be generally circular such that the first and second substrate materials 106, 108 define a generally cylindrical shape extending between their opposing first and second ends. However, in other implementations, the first and second substrate materials 106, 108 may define a generally non-circular cross-section such that one or both of the first substrate material 106 or the second substrate material 108 may define a generally non-cylindrical shape between their opposing first and second ends. Alternatively, in other examples, one or both of the first substrate material 106 and the second substrate material 108 may have an asymmetric cross-section about an axis. In various implementations, each end of the first and second substrate materials 106, 108 may be axially aligned with an adjacent element. For example, the first end of the second substrate material 108 may be configured to be coaxially aligned when engaged with the second end of the first substrate material 106.

While various other implementations may use a variety of different heat sources, including, for example, resistive heat sources, induction heat sources, etc., in the illustrated implementation, the heat source 104 is configured to generate heat upon ignition. In the illustrated implementation, for example, the heat source 104 has a generally cylindrical shape and comprises a combustible fuel element incorporating a combustible carbonaceous material. In other implementations, the heat source 104 may have a different shape, for example, a prismatic shape with a cubic or hexagonal cross section. Carbonaceous materials generally have a high carbon content. Some exemplary carbonaceous materials may be primarily composed of carbon and/or may typically have a carbon content of greater than about 60 percent, commonly greater than about 70 percent, often greater than about 80 percent, and frequently greater than about 90 percent, on a dry weight basis.

In some cases, the heat source may incorporate elements other than combustible carbonaceous materials (e.g., tobacco components such as powdered tobacco or tobacco extract; flavorings; salts such as sodium chloride, potassium chloride, and sodium carbonate; thermostable graphite hollow cylindrical (e.g., tubing) fibers; iron oxide powder; glass filaments; powdered calcium carbonate; alumina granules; an ammonia source such as an ammonia salt; and/or binders such as guar gum, ammonium alginate, and sodium alginate). In other implementations, the heat source may comprise multiple ignitable objects, such as multiple ignitable beads. Note that in other implementations, the heat source may differ from those described above in terms of composition or relative content. For example, in some implementations, various forms of carbon, such as graphite or graphene, may be used as the heat source. In other implementations, the heat source may have increased levels of activated carbon, various porosities of carbon, various amounts of carbon, blends of any of the above-mentioned components, etc. In still other implementations, the heat source may comprise a non-carbon heat source, such as, for example, a flammable liquefied gas configured to generate heat upon ignition. For example, in some implementations, the liquefied gas may contain one or more of petroleum gas (LPG or LPG), propane, propylene, butylene, butane, isobutene, methylpropane, or n-butane. In still other implementations, the heat source may comprise a chemical reaction-based heat source, where ignition of the heat source comprises the interaction of two or more individual components. For example, a chemical reaction-based heat source may contain a metal agent and an activating solution, where contact between the metal agent and the activating solution activates the heat source. Some examples of chemical-based heat sources may be found in U.S. Patent No. 7,290,549 to Banerjee et al., which is incorporated herein by reference in its entirety. Combinations of heat sources are also possible.

In some cases, the heat source may incorporate elements other than combustible carbonaceous materials (e.g., tobacco components such as powdered tobacco or tobacco extract; flavorings; salts such as sodium chloride, potassium chloride, and sodium carbonate; thermostable graphite hollow cylindrical (e.g., tubing) fibers; iron oxide powder; glass filaments; powdered calcium carbonate; alumina granules; an ammonia source such as an ammonia salt; and/or binders such as guar gum, ammonium alginate, and sodium alginate). In other implementations, the heat source may contain multiple ignitable objects, such as multiple ignitable beads. Note that in other implementations, the heat source may differ from those described above in terms of composition or relative content. For example, in some implementations, various forms of carbon, such as graphite or graphene, may be used as the heat source. In other implementations, the heat source may have increased levels of activated carbon, various porosities of carbon, various amounts of carbon, blends of any of the above-mentioned components, etc. In still other implementations, the heat source may comprise a non-carbon heat source, such as, for example, a flammable liquefied gas configured to generate heat upon ignition. For example, in some implementations, the liquefied gas may include one or more of petroleum gas (LPG or LPG), propane, propylene, butylene, butane, isobutene, methylpropane, or n-butane. In still other implementations, the heat source may comprise a chemical reaction-based heat source, where ignition of the heat source involves the interaction of two or more individual components. For example, a chemical reaction-based heat source may contain a metal agent and an activating solution, where contact between the metal agent and the activating solution activates the heat source. Some examples of chemical-based heat sources may be found in U.S. Patent No. 7,290,549 to Banerjee et al., which is incorporated herein by reference in its entirety. Combinations of heat sources are also possible.

In other implementations, the heat source may be constructed in a variety of ways, but in some implementations, the heat source may contain extruded or compounded materials using crushed or powdered carbonaceous materials, having a density greater than about 0.5 g/cm ³ , often greater than about 0.7 g/cm ³ , and frequently greater than about 1 g/cm ³ on a dry weight basis. See, for example, the types of fuel source components, formulations, and designs described in U.S. Pat. No. 5,551,451 to Riggs et al. and U.S. Pat. No. 7,836,897 to Borschke et al., which are incorporated herein by reference in their entireties.

In various implementations, the heat source can have a variety of shapes, including, for example, a substantially solid cylindrical shape or a hollow cylindrical (e.g., tubular) shape; however, the heat source 104 in the illustrated implementation comprises an extruded monolithic carbonaceous material. In some implementations, the heat source can include multiple internal passages extending longitudinally from a first end of the heat source to an opposing second end of the heat source. Note that in other implementations, there need not be multiple internal passages, and/or the multiple internal passages can take various shapes and/or sizes, including generally cylindrical and generally non-cylindrical shapes. For example, in some implementations, there may be as few as one internal passage. Still other implementations may not include any internal passages at all. Additional implementations may include multiple internal passages that may be unequal in diameter and/or shape and may be unevenly spaced and/or disposed within the heat source.

The illustrated implementation includes a plurality of circumferential grooves 116 extending longitudinally from a first end of the heat source to an opposing second end. In other implementations, the grooves need not extend the entire length of the heat source. In the illustrated implementation, the grooves are substantially equal in width and depth and are substantially evenly distributed around the circumference of the heat source. However, other implementations may vary. For example, in some implementations, there may be as few as two grooves, while still other implementations may include as few as one groove. Still other implementations may not include any grooves at all. Additional implementations may include multiple grooves that may be unequal in width and/or depth and may be unevenly spaced around the circumference of the heat source. In still other implementations, the heat source may include flutes and/or slits extending longitudinally from a first end of the extruded monolithic carbonaceous material to its opposite second end. In some implementations, the heat source may include a foamed carbon monolith formed in a foaming process of the type disclosed in U.S. Patent No. 7,615,184 to Lobovsky, which is incorporated herein by reference in its entirety. Accordingly, some implementations may provide advantages in terms of reducing the time it takes to ignite the heat source. In some other implementations, the heat source may be co-extruded with a layer of insulation (not shown), thereby reducing manufacturing time and costs. Other implementations of the fuel element include carbon fiber of the type described in U.S. Patent No. 4,922,901 to Brooks et al., or other heat source implementations such as those disclosed in U.S. Patent Application Publication No. 2009/0044818 to Takeuchi et al., each of which is incorporated herein by reference in its entirety. Further examples of heat sources, including debossing heat source systems, methods, and smoking articles including such heat sources are disclosed in U.S. Patent Application No. 15/902,665, filed February 22, 2018, and entitled "System for Debossing a Heat Generation Member, a Smoking Article Including the Debossed Heat Generation Member, and a Related Method," which is incorporated herein by reference in its entirety.

Generally, the heat source is positioned sufficiently close to the aerosol delivery component (e.g., substrate material) having one or more aerosolizable components such that the aerosol (and any flavoring materials, medicaments, etc. similarly provided for delivery to the user) formed/volatilized by the application of heat from the heat source to the aerosolizable component is deliverable to the user through the mouthpiece. That is, when the heat source heats the substrate material, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the foregoing terms are meant to be interchangeable to include references to release, releasing, releases, or released, including form or generate, forming or generating, forms or generated, and formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol, or a mixture thereof. Furthermore, the selection of various smoking article components will be understood in light of commercially available electronic smoking articles, such as the representative products listed in the Background section of this disclosure.

As noted above, the illustrated implementation includes a first substrate material 106 and a second substrate material 108, although other implementations may include a single substrate material. Still other implementations may include additional substrate materials. In some implementations, one or more of the substrate materials may contain a flavorful, aromatic tobacco blend in cut filler form. In other implementations, one or more of the substrate materials may contain a reconstituted tobacco material, such as those described in U.S. Pat. Nos. 4,807,809 to Pryor et al., 4,889,143 to Pryor et al., and 5,025,814 to Raker, the entire disclosures of which are incorporated herein by reference. Additionally, the reconstituted tobacco material may include reconstituted tobacco paper for cigarettes of the type described in "Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco Company Monograph" (1988), the entire contents of which are incorporated herein by reference. For example, the reconstituted tobacco material may include a sheet-like material containing tobacco and/or tobacco-related materials. Thus, in some implementations, one or more of the substrate materials may be formed from a wound roll of reconstituted tobacco material. In other implementations, one or more of the substrate materials may be formed from shreds, strips, or the like of reconstituted tobacco material. In another implementation, the tobacco sheet may include overlapping layers (e.g., gathered webs) that may or may not include thermally conductive components. An example of a substrate material including a series of overlapping layers (e.g., gathered webs) of an initial substrate sheet formed by a fibrous filler material, an aerosol-forming material, and multiple thermally conductive components is described in U.S. Patent Application No. 15/905,320, filed February 26, 2018, and entitled "Heat Conducting Substrate for Electrically Heated Aerosol Delivery Device," which is incorporated herein by reference in its entirety.

In some implementations, one or more of the substrate materials may include a plurality of microcapsules, beads, granules, etc. having tobacco-related material. For example, a typical microcapsule may be approximately spherical in shape and may have an outer cover or shell containing a liquid center region, such as a tobacco-derived extract. In some implementations, one or more of the substrate materials may include a plurality of microcapsules, each formed in a hollow cylindrical shape. In some implementations, one or more of the substrate materials may include a binder material configured to maintain the structural shape and/or integrity of the plurality of microcapsules formed in a hollow cylindrical shape.

The tobacco used in one or more of the substrate materials may include or be derived from tobaccos such as flue-cured, burley, Oriental, Maryland, dark, dark-flavored, and rustica tobaccos, as well as other rare or specialty tobaccos, or blends thereof. Various representative tobacco types, tobacco processing types, and tobacco blend types are described in U.S. Patent Nos. 4,836,224 to Lawson et al., 4,924,888 to Perfetti et al., 5,056,537 to Brown et al., 5,159,942 to Brinkley et al., 5,220,930 to Gentry, and 5,360 to Blackley et al., the entire disclosures of which are incorporated herein by reference. No. 6,701,936 to Shafer et al., U.S. Pat. No. 6,730,832 to Dominguez et al., U.S. Pat. No. 7,011,096 to Li et al., U.S. Pat. No. 7,017,585 to Li et al., U.S. Pat. No. 7,025,066 to Lawson et al., U.S. Patent Application Publication No. 2004/0255965 to Perfetti et al., PCT Publication No. WO 02/37990 to Bereman, and Fund. Appl. Toxicol., 39, pp. 11-17 (1997) to Bombick et al.

In still other implementations of the present disclosure, one or more of the substrate materials may be configured as an extruded structure that includes or consists essentially of tobacco, tobacco-related materials, glycerin, water, and/or binder materials, although certain formulations may be binder-free. In various implementations, suitable binder materials may include alginates, such as ammonium alginate, propylene glycol alginate, potassium alginate, and sodium alginate. Alginates, particularly high-viscosity alginates, may be used in combination with controlled levels of free calcium ions. Other suitable binder materials include hydroxypropyl cellulose, such as Klucel H from Aqualon Co.; hydroxypropyl methylcellulose, such as Methocel K4MS from The Dow Chemical Co.; and hydroxypropyl methylcellulose, such as Methocel K4MS from Aqualon Co. Examples of suitable binder materials include hydroxyethylcellulose, such as Natrosol 250 MRCS from FMC; microcrystalline cellulose, such as Avicel from FMC; methylcellulose, such as Methocel A4M from The Dow Chemical Co.; and sodium carboxymethylcellulose, such as CMC 7HF and CMC 7H4F from Hercules Inc. Still other possible binder materials include starch (e.g., corn starch), guar gum, carrageenan, locust bean gum, pectin, and xanthan gum. In some implementations, a combination or blend of two or more binder materials may be used. Other examples of binder materials are described, for example, in U.S. Pat. No. 5,101,839 to Jakob et al. and U.S. Pat. No. 4,924,887 to Raker et al., each of which is incorporated herein by reference in its entirety. In some implementations, the aerosol-forming material may be provided as part of the binder material (e.g., propylene glycol alginate). Additionally, in some implementations, the binder material may contain nanocellulose derived from tobacco or other biomass.

In some implementations, one or more of the substrate materials may be configured as an extruded material, as described in U.S. Patent Application Publication No. 2012/0042885 to Stone et al., which is incorporated herein by reference in its entirety. In yet another implementation, one or more of the substrate materials may include an extruded structure and/or substrate formed from marumerized and/or non-marumerized tobacco. Marumerized tobacco is known, for example, from U.S. Patent No. 5,105,831 to Banerjee et al., which is incorporated herein by reference in its entirety. Marumerized tobacco includes about 20 to about 50 percent (by weight) of a tobacco blend in powder form, along with glycerol (about 20 to about 30 percent by weight), calcium carbonate (generally about 10 to about 60 percent by weight, often about 40 to about 60 percent by weight), in combination with a binder and/or flavoring as described herein. In various implementations, the extruded material may have one or more longitudinal openings.

In various implementations, one or more of the substrate materials may have different configurations based on the varying amounts of materials utilized therein. For example, exemplary substrate materials may contain up to about 98%, up to about 95%, or up to about 90% by weight of tobacco and/or tobacco-related materials. Exemplary substrate materials may also contain up to about 25%, about 20%, or about 15% by weight of water, particularly about 2% to about 25%, about 5% to about 20%, or about 7% to about 15% by weight of water. Flavors and the like (including, for example, agents such as nicotine) may contain up to about 10%, up to about 8%, or up to about 5% by weight of the aerosol delivery components.

Additionally or alternatively, one or more of the substrate materials may be configured as an extruded structure and/or substrate that includes or consists essentially of tobacco, glycerin, water, and/or a binder material, and is further configured to substantially maintain its structure throughout the aerosol generation process. That is, one or more of the substrate materials may be configured to substantially maintain its shape throughout the aerosol generation process (e.g., the substrate material does not continuously deform under applied shear stress). While such exemplary substrate materials may include liquid and/or some moisture content, the substrate may remain substantially solid throughout the aerosol generation process and may substantially maintain its structural integrity throughout the aerosol generation process. Exemplary tobacco and/or tobacco-related materials suitable for the substantially solid substrate material are described in U.S. Patent Application Publication No. 2015/0157052 to Ademe et al., U.S. Patent Application Publication No. 2015/0335070 to Sears et al., U.S. Patent No. 6,204,287 to White, and U.S. Patent No. 5,060,676 to Hearn et al., which are incorporated by reference in their entireties.

In some implementations, the amount of substrate material used in a smoking article may be such that the article exhibits acceptable sensory and organoleptic properties, as well as desirable performance characteristics. For example, in some implementations, an aerosol precursor composition, such as glycerin and/or propylene glycol, may be used in the substrate material to generate a visible mainstream aerosol that resembles in many respects the appearance of tobacco smoke. For example, the amount of aerosol precursor composition incorporated into the substrate material of a smoking article may range from about 3.5 grams or less, about 3 grams or less, about 2.5 grams or less, about 2 grams or less, about 1.5 grams or less, about 1 gram or less, or about 0.5 grams or less.

According to another implementation, a smoking article according to the present disclosure may include one or more substrate materials comprising a porous inert material, such as, for example, a ceramic material. For example, in some implementations, ceramics of various shapes and configurations (e.g., beads, rods, tubes, etc.) with various pore morphologies may be used. Furthermore, in some implementations, a non-tobacco material, such as e-liquid, may be supported on the ceramic. In another implementation, one or more of the substrate materials may include a porous inert material that is substantially chemically and/or physically unreactive with tobacco-related materials, such as tobacco-derived extracts. Furthermore, extruded tobacco, such as that described above, may be porous. For example, in some implementations, the extruded tobacco material may have an inert gas, such as nitrogen, that acts as a foaming agent during the extrusion process.

As noted above, in various implementations, one or more of the substrate materials may include tobacco, tobacco components, and/or tobacco-derived materials that have been processed, manufactured, produced, and/or processed to incorporate an aerosol precursor composition (e.g., a humectant, e.g., propylene glycol, glycerin, etc.) and/or at least one flavoring, as well as a flame retardant/flame retardant (e.g., diammonium phosphate and/or another salt) configured to help prevent ignition, thermal decomposition, combustion, and/or charring of the substrate material by a heat source. Various modes and methods for incorporating tobacco into smoking articles, particularly smoking articles designed to intentionally prevent the combustion of substantially any tobacco within the smoking article, are described in U.S. Pat. No. 4,947,874 to Brooks et al., U.S. Pat. No. 7,647,932 to Cantrell et al., U.S. Pat. No. 8,079,371 to Robinson et al., U.S. Pat. No. 7,290,549 to Banerjee et al., and U.S. Patent Application Publication No. 2007/0215167 to Crooks et al., the entire disclosures of which are incorporated herein by reference.

As previously mentioned, in some implementations, flame-retardant/flame-retardant materials and other additives may be included in one or more of the substrate materials and may include organophosphorus compounds, borax, hydrated alumina, graphite, potassium tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Others, such as nitrogen phosphonates, monoammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ethanolammonium borate, ammonium sulfamate, halogenated organic compounds, thiourea, and antimony oxide, are also suitable but are not preferred agents. In each aspect of the flame-retardant, flame-retardant, and/or char-retardant materials used in the substrate materials and/or other components (whether alone or in combination with each other and/or other materials), the desired properties are most preferably provided without undesirable outgassing or melting behavior.

According to other implementations of the present disclosure, one or more of the substrate materials may also incorporate tobacco additives of the type conventionally used in the manufacture of tobacco products. These additives may include materials of the type used to enhance the flavor and aroma of tobacco used in the manufacture of cigars, cigarettes, pipes, and the like. For example, these additives may include various cigarette flavoring components and/or top layer components. See, for example, U.S. Pat. No. 3,419,015 to Wochnowski, U.S. Pat. No. 4,054,145 to Berndt et al., U.S. Pat. No. 4,887,619 to Burcham, Jr. et al., U.S. Pat. No. 5,022,416 to Watson, U.S. Pat. No. 5,103,842 to Strang et al., and U.S. Pat. No. 5,711,320 to Martin, the disclosures of which are incorporated herein by reference in their entireties. Some flavoring ingredients may include water, sugars and syrups (e.g., sucrose, glucose, and high fructose corn syrup), humectants (e.g., glycerin or propylene glycol), and flavorings (e.g., cocoa and licorice). These additional ingredients may also include top layer materials (e.g., flavoring materials such as menthol). See, for example, U.S. Pat. No. 4,449,541 to Mays et al., the entire disclosures of which are incorporated herein by reference. Additional materials that may be added include those disclosed in U.S. Pat. No. 4,830,028 to Lawson et al. and U.S. Pat. No. 8,186,360 to Marshall et al., the entire disclosures of which are incorporated herein by reference.

As noted above, in various implementations, one or more of the substrate materials can have an aerosol precursor composition bound thereto. For example, in some implementations, the aerosol precursor composition may contain one or more different components, such as a polyhydric alcohol (e.g., glycerin, propylene glycol, or mixtures thereof). Representative types of additional aerosol precursor compositions are described in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al., U.S. Pat. No. 5,101,839 to Jakob et al., PCT Publication No. WO 98/57556 to Biggs et al., and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J., the disclosures of which are incorporated herein by reference. Reynolds Tobacco Company Monograph (1988). In some aspects, the substrate material can generate a visible aerosol when sufficient heat is applied (and optionally cooled by air), and the substrate material may generate a "smoky" aerosol. In other aspects, the substrate material can generate an aerosol that is substantially invisible but whose presence is recognized by other characteristics, such as flavor or texture. Thus, the nature of the aerosol generated may vary depending on the specific components of the aerosol delivery component. The substrate material may be chemically simple compared to the chemistry of the smoke generated by burning tobacco.

In some implementations, the aerosol precursor composition may incorporate nicotine, which may be present in various concentrations. The source of the nicotine may vary, and the nicotine incorporated in the aerosol precursor composition may be derived from a single source or a combination of two or more sources. For example, in some implementations, the aerosol precursor composition may include nicotine derived from tobacco. In other implementations, the aerosol precursor composition may include nicotine derived from other organic plant sources, such as non-tobacco plant sources including plants of the Solanaceae family. In other implementations, the aerosol precursor composition may include synthetic nicotine. In some implementations, the nicotine incorporated in the aerosol precursor composition may be derived from non-tobacco plant sources, such as other members of the Solanaceae family. The aerosol precursor composition may further comprise one or more active ingredients, including, but not limited to, nicotine components, botanical components (e.g., lavender, peppermint, chamomile, basil, rosemary, ginger, cannabis, ginseng, maca, hemp, eucalyptus, rooibos, fennel, citrus, clove, and tisane), stimulants (e.g., caffeine and guarana), amino acids (e.g., taurine, theanine, phenylalanine, tyrosine, and tryptophan), and/or pharmaceutical, nutraceutical, and medicinal components (e.g., vitamins, e.g., B6, B12, and C, and/or cannabinoids, e.g., tetrahydrocannabinol (THC) and cannabidiol (CBD)). The specific proportions and selection of ingredients will vary depending on the desired flavor, texture, and other characteristics. Exemplary active ingredients can include any ingredient known to affect one or more biological functions in the body, for example, ingredients that provide pharmacological activity or other direct effect on the diagnosis, cure, mitigation, treatment, or prevention of disease, or that affect the structure or any function of the human or other animal body (e.g., provide a stimulating effect on the central nervous system, have an energizing, antipyretic, or analgesic effect, or other beneficial effect on the body).

A wide variety of flavorings or materials that alter the sensory or organoleptic characteristics or properties of the mainstream aerosol of a smoking article may be suitable for use. In some implementations, such flavorings may be provided from sources other than tobacco and may be natural or artificial in nature. For example, some flavorings may be applied to or incorporated into the substrate material and/or the region of the smoking article where the aerosol is generated. In some implementations, such agents may be provided directly to the heating cavity or region proximate the heat source or provided with the substrate material. Exemplary flavors may include, for example, 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 flavors and flavor packages of the type and characteristics conventionally used in cigarette, cigar, and pipe tobacco flavorings. Syrups, such as high fructose corn syrup, may also be suitable for use.

Flavorings may also include acidic or basic properties (e.g., organic acids such as levulinic acid, succinic acid, and pyruvic acid). In some implementations, flavorings may be combined with elements of the substrate material, if desired. Exemplary plant-derived compositions that may be suitable are disclosed in U.S. Patent No. 9,107,453 and U.S. Patent Application Publication No. 2012/0152265, both to Dube et al., the disclosures of which are incorporated herein by reference in their entireties. Any of the materials, such as flavorings, aromas, and the like, that may be useful in combination with tobacco materials to affect their sensory properties, including those described herein, may also be combined with the substrate material. In particular, organic acids may be incorporated into the substrate material to affect the flavor, sensory, or organoleptic properties of agents such as nicotine that may be combined with the substrate material. For example, organic acids such as levulinic acid, lactic acid, and pyruvic acid may be included in the substrate material along with nicotine in amounts up to equimolar with nicotine (based on total organic acid content). Any combination of organic acids may be suitable. For example, in some implementations, the substrate material may include about 0.1 to about 0.5 moles of levulinic acid per mole of nicotine, about 0.1 to about 0.5 moles of pyruvic acid per mole of nicotine, about 0.1 to about 0.5 moles of lactic acid per mole of nicotine, or combinations thereof, up to a concentration where the total amount of organic acids present is equimolar to the total amount of nicotine present in the substrate material. Various additional examples of organic acids used to produce substrate materials are described in U.S. Patent Application Publication No. 2015/0344456 to Dull et al., which is incorporated herein by reference in its entirety.

The selection of such additional ingredients may vary based on factors such as the sensory characteristics desired in the smoking article, and the present disclosure is intended to encompass any such additional ingredients that would be readily apparent to one 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 entire disclosures of which are incorporated herein by reference.

In other implementations, one or more of the substrate materials may include other materials with various unique characteristics or properties. For example, one or more of the substrate materials may include a plasticized material in the form of rayon or regenerated cellulose. As another example, viscose (commercially available as VISIL®), a regenerated cellulose product incorporating silica, may be suitable. Some carbon fibers may contain at least 95 percent carbon or more. Similarly, natural cellulose fibers such as cotton may be suitable, and may be infused with or treated with silica, carbon, or metal particles to enhance flame retardant properties and, in particular, minimize the outgassing of any undesirable outgassing components that would adversely affect flavor (especially minimizing the potential for any harmful outgassing products). Cotton may be treated with, for example, boric acid or various organophosphate compounds to provide desirable flame retardant properties by soaking, spraying, or other techniques known in the art. These fibers may also be treatable (e.g., coated by dipping, spraying, or vapor deposition, impregnated, or both) with organic or metallic nanoparticles to impart desired flame-retardant properties without undesirable outgassing or melt-type behavior.

Although other implementations may vary, in the illustrated implementation, the outer wrap 102 (most clearly shown in FIG. 1 ) is provided to engage or otherwise join at least a portion of the heat source 104 with the first substrate material 106, the second substrate material 108, and at least a portion of the mouthpiece 114. Thus, in some aspects, the outer wrap material 102 is configured to surround, e.g., coaxially surround, at least a portion of the heat source 104, the first substrate material 106 engaged with the heat source 104 around a first end thereof, the second substrate material 108 engaged with a second end of the first substrate material 106, and at least a portion of the mouthpiece 114. The outer wrap 102 is configured to be held in place in any manner, e.g., via adhesive or fasteners, allowing the outer wrap 102 to remain in the wrapped position. Alternatively, in some other aspects, the outer wrap 102 may be configured to be removable as desired. For example, holding the outer wrap 102 in the wrapped position may allow the outer wrap 102 to be removed from the heat source 104, the first substrate material 106 engaged with the heat source 104 around its first end, the second substrate material 108 engaged with the second end of the first substrate material 106, and/or the mouthpiece 114.

In the illustrated implementation, the outer wrap 102 also includes one or more openings 120 formed therethrough that allow air to enter upon inhalation on the mouthpiece 114. In various implementations, the size and number of these openings can be adjusted so that a majority of the drawn airflow occurs through these openings (in some implementations, a high airflow rate) and a minority of the airflow occurs through the hollow structure described below (in some implementations, a low airflow rate). In this manner, the airflow through the hollow structure can be solely or primarily for the purpose of promoting heat transfer. In the illustrated implementation, multiple substantially equally spaced openings 120 are formed in the outer wrap 102 in the region adjacent to the first substrate material 106, and multiple substantially equally spaced separate openings 122 are formed in the outer wrap 102 in the region adjacent to the mouthpiece 114. While in various implementations, the multiple openings can be formed through the outer wrap 102 in various ways, in the illustrated implementation, the multiple openings are formed via laser drilling.

In various implementations of the present invention, the downstream flavoring component provides one or more flavors to the aerosol generated by heating the substrate material. Figure 3 shows a longitudinal schematic view of a smoking article according to one implementation of the present invention. In particular, Figure 3 shows a smoking article 200 including a heat source 204, a first substrate material 206, a second substrate material 208, a filter 210, and a downstream flavoring component 212. In the illustrated implementation, the filter 210 and the flavoring component 212 together comprise a mouthpiece 214. In the illustrated implementation, the heat source 204 comprises a combustible fuel element. However, in alternative implementations (e.g., consumables for use with ETHP devices), the heat source may be removed, and the smoking article may be engaged with an electrically powered device capable of heating the consumable, or portions thereof (e.g., by resistive and/or inductive heating—see, e.g., Figure 6 ). See the above discussion for further information regarding possible heat sources and variations thereof. In the illustrated implementation, the first substrate material 206 and the second substrate material 208 may contain the same or different materials. See the above discussion of possible substrate materials and variations thereof. See also the above discussion of possible filters and variations thereof.

In the illustrated implementation, the flavoring component 212 comprises a plurality of flavor beads 224 and a generally hollow flow tube 226. In various implementations, the flow tube may be made from a variety of different materials, including, for example, a metallic material (e.g., stainless steel), a plastic material, or other materials such as cellulose acetate. In the illustrated implementation, the flow tube 226 comprises a plurality of openings 228 disposed about the circumference of the flow tube 226, although other configurations are possible. The plurality of openings 228 in the illustrated implementation are disposed in an area proximate to the plurality of flavor beads 224. However, in other implementations, the plurality of openings may have other locations and/or extend beyond the area of the flavor beads. In the illustrated implementation, the plurality of openings 228 comprise a plurality of slots, although in other implementations, the plurality of openings may have other configurations. For example, in some implementations, the plurality of openings comprise a plurality of holes.

In various implementations, the flavor beads may contain one or more of tobacco flavor beads (e.g., maruminated tobacco beads), non-tobacco flavor beads, gel flavor beads, capsules containing flavor beads, or any combination thereof. In various implementations, the flavor beads may include one or more flavors that may alter the sensory or organoleptic characteristics or properties of the mainstream aerosol of the smoking article in which they may be suitable for use. In some implementations, such flavors may be provided from a tobacco source or a source other than tobacco, and may be natural or artificial in nature. Exemplary flavors may include, for example, 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 flavors and flavor packages of the types and characteristics traditionally used in cigarette, cigar, and pipe tobacco flavorings. Syrups such as high fructose corn syrup may also be suitable for use. In some implementations, the flavor of the multiple flavor beads may be the only flavor added to the aerosol. In other implementations, the flavor of the multiple flavor beads may be in addition to the flavor contained in the substrate material.

In the illustrated implementation, the flow tube 226 extends from the distal end of the mouthpiece 214 along its longitudinal axis through at least a portion of the filter 210. Note that in other implementations, the flow tube need not extend into the filter. In various implementations, the plurality of flavor beads may be proximate to at least a portion of the flow tube. In some implementations, the plurality of flavor beads may substantially surround at least a portion of the flow tube. In the illustrated implementation, the plurality of flavor beads 224 substantially surrounds more than half of the longitudinal length of the flow tube 226. However, in other implementations, the plurality of flavor beads may substantially surround less than half of the longitudinal length of the flow tube. In some implementations, the plurality of flavor beads may be disposed proximate to a portion of the substrate material.

As noted above, various other types of heat sources are possible. For example, FIG. 6 shows a longitudinal schematic view of a smoking article according to another implementation of the present disclosure. In various respects, the illustrated smoking article 500 is similar to that shown in FIG. 3 (see further description thereof). For example, the smoking article 500 includes a first substrate material 506, a second substrate material 508, a filter 510, both of which include a mouthpiece 514, and a downstream flavoring component 512. In the illustrated implementation, the flavoring component 512 includes a plurality of flavor beads 524 and a generally hollow flow tube 526 having a plurality of openings 528 disposed about the periphery of the flow tube 526. The plurality of openings 528 in the illustrated implementation are disposed in an area adjacent to the plurality of flavor beads 524. However, in the illustrated implementation, the heat source 504 represents an electrical heat source, such as a resistive or inductive heat source, which may be part of a device separate from the smoking article 500. It should be noted that in various implementations, the heat source may or may not be in physical contact with the substrate material, and the heat source may have any configuration, including, for example, a configuration in proximity to (or in some implementations in contact with) the periphery of at least a portion of the substrate material and/or a configuration in proximity to (or in some implementations in contact with) an edge of the substrate material.

FIG. 4 shows a longitudinal schematic view of a smoking article according to another implementation of the present invention. In particular, FIG. 4 shows a smoking article 300 including a heat source 304, a first substrate material 306, a second substrate material 308, a filter 310, and a downstream flavoring component 312. In the illustrated implementation, the filter 310 and the flavoring component 312 together comprise a mouthpiece 314. In the illustrated implementation, the heat source 304 comprises a combustible fuel element. However, in alternative implementations (e.g., consumables for use with ETHP devices), the heat source may be removed, and the smoking article may be engaged with an electrically powered device capable of heating the consumable, or portions thereof (e.g., by resistive heating and/or induction heating—see, e.g., FIG. 7 ). See further the discussion above regarding possible heat sources and variations thereof. In the illustrated implementation, the first substrate material 306 and the second substrate material 308 may comprise the same or different materials. See above for possible substrate materials and variations thereof. Also see above for possible filters and variations thereof.

In the illustrated implementation, the flavor-adding component 312 contains a plurality of flavor beads 324. In various implementations, the flavor beads may contain one or more of tobacco flavor beads, non-tobacco flavor beads, gel flavor beads, capsules containing flavor beads, or any combination thereof. In various implementations, the flavor beads may include one or more flavors that may alter the sensory or organoleptic characteristics or properties of the mainstream aerosol of the smoking article in which they may be suitable for use. In some implementations, such flavors may be provided from a tobacco source or a source other than tobacco, and may be natural or artificial in nature. Exemplary flavors may include, for example, 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 flavors and flavor packages of the types and characteristics traditionally used in cigarette, cigar, and pipe tobacco flavorings. Syrups such as high fructose corn syrup may also be suitable for use. In some implementations, the flavor of the multiple flavor beads may be the only flavor added to the aerosol. In other implementations, the flavor of the multiple flavor beads may be in addition to the flavor contained in the substrate material.

In the illustrated implementation, the filter 310 includes a cavity 330, with a plurality of flavor beads 324 disposed within the cavity 330. In the illustrated implementation, the cavity 330 is approximately centrally located along the longitudinal length of the filter 310, although in other implementations the cavity may be located near either end of the filter or any other location along the length of the filter. Furthermore, while in the illustrated implementation there is a single cavity 330, in other implementations there may be multiple cavities, with the same or different flavor beads disposed within one or more of the cavities.

As noted above, various other types of heat sources are possible. For example, FIG. 7 shows a longitudinal schematic view of a smoking article according to another implementation of the present disclosure. In various respects, the illustrated smoking article 600 is similar to that shown in FIG. 4 (see further description thereof). For example, the smoking article 600 includes a first substrate material 606, a second substrate material 608, a filter 610, both having a mouthpiece 614, and a downstream flavoring component 612. The filter 610 includes a cavity 630, and a plurality of flavor beads 624 are disposed within the cavity 630. However, in the illustrated implementation, the heat source 504 represents an electrical heat source, such as a resistive or inductive heat source, which may be part of a device separate from the smoking article 500. It should be noted that in various implementations, the heat source may or may not be in physical contact with the substrate material, and the heat source may have any configuration, including, for example, proximate to (or, in some implementations, contacting) the periphery of at least a portion of the substrate material and/or proximate to (or, in some implementations, contacting) an edge of the substrate material. Figure 5 shows a longitudinal schematic view of a smoking article according to another implementation of the present invention. In particular, Figure 5 shows a smoking article 400 including a heat source 404, a first substrate material 406, a second substrate material 408, a filter 410, and a downstream flavoring component 412. In the illustrated implementation, the filter 410 and the flavoring component 412 together comprise a mouthpiece 414. In the illustrated implementation, the heat source 404 comprises a combustible fuel element. However, in alternative implementations (e.g., consumables for use with ETHP devices), the heat source may be removed and the smoking article may be engaged with an electrically powered device capable of heating the consumable or portions thereof (e.g., by resistive and/or inductive heating—see, e.g., FIG. 8 ). See the above discussion regarding possible heat sources and variations thereof. In the illustrated implementation, the first substrate material 406 and the second substrate material 408 may comprise the same or different materials. See the above discussion regarding possible substrate materials and variations thereof. See also the above discussion regarding possible filters and variations thereof.

In the illustrated implementation, the flavoring component 412 comprises a plurality of flavor beads 424 and a generally hollow flow tube 426. In the illustrated implementation, the flow tube 426 includes a plurality of openings 428 disposed about the circumference of the flow tube 426, although other configurations are possible. The plurality of openings 428 in the illustrated implementation are located in an area proximate to the plurality of flavor beads 424. However, in other implementations, the plurality of openings may have other locations and/or extend beyond the area of the flavor beads. In the illustrated implementation, the plurality of openings 428 include a plurality of slots, although in other implementations, the plurality of openings may have other configurations. For example, in some implementations, the plurality of openings comprises a plurality of holes.

In various implementations, the flavor beads may contain one or more of tobacco flavor beads, non-tobacco flavor beads, gel flavor beads, capsules containing flavor beads, or any combination thereof. In various implementations, the flavor beads may include one or more flavors that may alter the sensory or organoleptic characteristics or properties of the mainstream aerosol of the smoking article in which they may be suitable for use. In some implementations, such flavors may be provided from a tobacco source or a source other than tobacco, and may be natural or artificial in nature. Exemplary flavors may include, for example, 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 flavors and flavor packages of the types and characteristics traditionally used in cigarette, cigar, and pipe tobacco flavorings. Syrups such as high fructose corn syrup may also be suitable for use. In some implementations, the flavor of the multiple flavor beads may be the only flavor added to the aerosol. In other implementations, the flavor of the multiple flavor beads may be in addition to the flavor contained in the substrate material.

In the illustrated implementation, the filter includes a cavity 430, with a plurality of flavor beads 424 disposed within the cavity 430. In the illustrated implementation, the cavity 430 is approximately centrally located along the longitudinal length of the filter 410; however, in other implementations, the cavity may be located near either end of the filter or at any other location along the length of the filter. Furthermore, while there is a single cavity 430 in the illustrated implementation, there may be multiple cavities in other implementations, with the same or different flavor beads disposed within one or more of the cavities. In the illustrated implementation, the flow tube 426 extends from the distal end of the mouthpiece 414 through at least a portion of the filter 410 along its longitudinal axis. Note that in other implementations, the flow tube need not extend into the filter. In various implementations, the plurality of flavor beads may be adjacent to at least a portion of the flow tube. In some implementations, the plurality of flavor beads may substantially surround at least a portion of the flow tube. In the illustrated implementation, the plurality of flavor beads 424 substantially surrounds more than half of the longitudinal length of the flow tube. However, in other implementations, the plurality of flavor beads may substantially surround less than half of the longitudinal length of the flow tube.

As noted above, various other types of heat sources are possible. For example, FIG. 8 shows a longitudinal schematic view of a smoking article according to another implementation of the present disclosure. In various respects, the illustrated smoking article 700 is similar to that shown in FIG. 5 (see further description thereof). For example, the smoking article 700 includes a first substrate material 706, a second substrate material 708, a filter 710, both of which include a mouthpiece 714, and a downstream flavoring component 712. In the illustrated implementation, the flavoring component 712 includes a plurality of flavor beads 724 and a generally hollow flow tube 726. Although other configurations are possible, in the illustrated implementation, the flow tube 726 includes a plurality of openings 728 disposed about the periphery of the flow tube 726. The plurality of openings 728 in the illustrated implementation are located in an area adjacent to the plurality of flavor beads 724. The filter includes a cavity 730, and the plurality of flavor beads 724 are disposed within the cavity 730. However, in the illustrated implementation, the heat source 704 represents an electrical heat source, such as a resistive or inductive heat source, which may be part of a device separate from the smoking article 700. It should be noted that in various implementations, the heat source may or may not be in physical contact with the substrate material, and the heat source may have any configuration, including, for example, a configuration in proximity to (or in some implementations in contact with) the periphery of at least a portion of the substrate material and/or a configuration in proximity to (or in some implementations in contact with) the edge of the substrate material.

Smoking articles according to the present disclosure may take on a variety of implementations, as described in detail herein, although the use of the smoking article by a consumer will be similar in scope. The above description of the use of a smoking article is applicable to the various implementations described, with minor modifications that will be apparent to those skilled in the art in light of the further disclosure provided herein. However, the description of use is not intended to limit the use of the article of the present invention, but is provided to fulfill all necessary requirements of the disclosure herein.

Many modifications and other embodiments of the present disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the present disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims (11)

at least one substrate material portion having an aerosol precursor composition bound thereto ;
a mouthpiece positioned downstream of the heat source and the at least one substrate material portion;
a smoking article comprising: a mouthpiece including a filter;
the mouthpiece includes a flavoring component, the flavoring component containing a plurality of flavor beads adjacent to a hollow flow tube, the flow tube including a plurality of peripheral openings defined therethrough;
the hollow flow tube extends through at least a portion of the plurality of flavor beads and beyond the plurality of flavor beads;
Smoking products. The smoking article of claim 1, wherein the flavor-adding component is positioned downstream of the filter. The smoking article of claim 1, wherein the flow tube extends through at least a portion of the filter. The smoking article of claim 1, wherein the filter defines a cavity, the plurality of flavor beads are disposed within the cavity, and the flow tube extends through at least a portion of the filter. further comprising a heat source, the heat source being disposed proximate to at least a portion of the at least one substrate material portion; and optionally
10. The smoking article of claim 1, wherein the heat source comprises a combustible heat source. 10. The smoking article of claim 1, further comprising a device separate from the smoking article, the separate device including an electric heat source configured to heat at least a portion of the at least one substrate material portion. 2. A smoking article according to claim 1, wherein the plurality of peripheral openings of the flow tube comprise a plurality of holes extending through the peripheral wall of the flow tube. 10. A smoking article according to claim 1, wherein the plurality of peripheral openings of the flow tube comprise a plurality of slots extending through the peripheral wall of the flow tube. 10. The smoking article of claim 1, wherein the plurality of flavor beads comprises at least one of tobacco flavor beads, non-tobacco flavor beads, gel flavor beads, capsules containing flavor beads, or any combination thereof. 10. The smoking article of claim 1, further comprising a second substrate material disposed between the first substrate material and the mouthpiece. 10. The smoking article of claim 1, wherein the substrate material comprises at least one of tobacco-containing beads, shredded tobacco, strips of tobacco, pieces of reconstituted tobacco material, or tobacco rods.