Smoking article with heat transfer component

Smoking articles are disclosed herein. The present disclosure is directed to a smoking article that comprises a heat source configured to generate heat upon ignition thereof, a substrate material having opposed first and second ends, the heat source being disposed proximate the first end of the substrate material and the substrate material having an aerosol precursor composition associated therewith, a mouthpiece, the mouthpiece being disposed proximate the second end of the substrate material, and a heat transfer component. In one implementation, the heat transfer component comprises a hollow structure and opposing first and second flanges located on respective ends thereof, wherein the hollow structure extends through the heat source such that the heat source is located between the first and second opposing flanges. In another implementation, the heat transfer component is located within the heat source, penetrates at least a portion of the substrate material, and includes a cap located between the heat source and the substrate material.

FIELD OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices and systems, such as smoking articles; and more particularly, to aerosol delivery devices and systems that utilize combustible carbon-based ignition sources for the production of aerosol (e.g., smoking articles for purposes of yielding components of tobacco and other materials in an inhalable form, commonly referred to as heat-not-burn systems or electronic cigarettes). Components of such articles are made or derived from tobacco, or those articles can be characterized as otherwise incorporating tobacco for human consumption, and which are capable of vaporizing components of tobacco and/or other tobacco related materials to form an inhalable aerosol for human consumption.

BACKGROUND

Many smoking articles have been proposed through the years as improvements upon, or alternatives to, smoking products based upon combusting tobacco. Example alternatives have included devices wherein a solid or liquid fuel is combusted to transfer heat to tobacco or wherein a chemical reaction is used to provide such 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.

The point of the improvements or alternatives to smoking articles typically has been to provide the sensations associated with cigarette, cigar, or pipe smoking, without delivering considerable quantities of incomplete combustion and pyrolysis products. To this end, there have been proposed numerous smoking products, flavor generators, and medicinal inhalers which utilize electrical energy to vaporize or heat a volatile material, or attempt to provide the sensations of cigarette, cigar, or pipe smoking without burning tobacco to a significant degree. See, for example, the various alternative smoking articles, aerosol delivery devices and heat generating sources set forth in the background art described in U.S. Pat. No. 7,726,320 to Robinson et al.; and U.S. Pat. App. Pub. 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 heat generating sources referenced by brand name and commercial source in U.S. patent. application. Pub. No. 2015/0220232 to Bless et al., which is incorporated herein by reference. Additional types of smoking articles, aerosol delivery devices and electrically powered heat generating sources referenced by brand name and commercial source are listed in U.S. Pat. App. Pub. 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 instances, been made commercially available include those described in 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. 5,388,594 to Counts et al.; 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. 7,513,253 to Kobayashi; U.S. Pat. No. 7,726,320 to Robinson et al.; U.S. Pat. No. 7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan; U.S. Pat. App. Pub. No. 2009/0095311 to Hon; U.S. Pat. App. Pub. Nos. 2006/0196518, 2009/0126745, and 2009/0188490 to Hon; U.S. Pat. App. Pub. No. 2009/0272379 to Thorens et al.; U.S. Pat. App. Pub. Nos. 2009/0260641 and 2009/0260642 to Monsees et al.; U.S. Pat. App. Pub. Nos. 2008/0149118 and 2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub. No. 2010/0307518 to Wang; and WO 2010/091593 to Hon, which are incorporated herein by reference.

Various manners and methods for assembling smoking articles that possess a plurality of sequentially arranged segmented components have been proposed. See, for example, the various types of assembly techniques and methodologies set forth in U.S. Pat. No. 5,469,871 to Barnes et al. and U.S. Pat. No. 7,647,932 to Crooks et al.; and U.S. Pat. App. Pub. 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 by reference herein in its entirety.

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

In some instances, traditional types of smoking articles, such as those referenced above, are difficult to assemble as a result of multiple components that must be disassembled and reassembled upon consumption of aerosol delivery components provided therein. In some other instances, some smoking articles, particularly those that employ a traditional paper wrapping material, are also prone to scorching of the paper wrapping material overlying an ignitable fuel source, due to the high temperature attained by the fuel source in proximity to the paper wrapping material. This can reduce enjoyment of the smoking experience for some consumers and can mask or undesirably alter the flavors delivered to the consumer by the aerosol delivery components of the smoking articles. In further instances, traditional types of smoking articles can produce relatively significant levels of gasses, such as carbon monoxide and/or carbon dioxide, during use (e.g., as products of carbon combustion). In still further instances, traditional types of smoking articles may suffer from poor performance with respect to aerosolizing the aerosol forming component(s).

As such, it would be desirable to provide smoking articles that address one or more of the technical problems sometimes associated with traditional types of smoking articles. In particular, it would be desirable to provide a smoking article that reduces carbon monoxide carbon dioxide, and/or other harmful products of carbon combustion, and/or provides improved heat transfer to the aerosol forming components.

BRIEF SUMMARY

In various implementations, the present disclosure provides a smoking article. In one implementation, the smoking article may comprise a heat source configured to generate heat upon ignition thereof, a substrate material having opposed first and second ends, the heat source being disposed proximate the first end of the substrate material, and the substrate material having an aerosol precursor composition associated therewith, a mouthpiece, the mouthpiece being disposed proximate the second end of the substrate material, and a heat transfer component comprising a hollow structure and including opposing first and seconds flanges located on respective ends thereof. The hollow structure of the heat transfer component may extend through the heat source such that the heat source is located between the first and second opposing flanges of the heat transfer component, and the hollow structure may be configured to permit the passage of air therethrough.

In some implementations, the substrate material may comprise at least one of tobacco-containing beads, tobacco shreds, tobacco strips, pieces of a reconstituted tobacco material, tobacco rods, and non-tobacco materials. Some implementations may further comprise a liner configured to circumscribe the substrate material and at least a portion of the heat source. Some implementations may further comprise one or more perforations located in the substrate material, the perforations being configured to facilitate airflow through the smoking article. Some implementations may further comprise a second substrate material having opposed first and second ends, the second substrate material being disposed between the first substrate material and the mouthpiece. In some implementations, the second substrate material may comprise at least one of tobacco-containing beads, tobacco shreds, tobacco strips, pieces of a reconstituted tobacco material, or tobacco rods. In some implementations, the mouthpiece may comprise an intermediate component. In some implementations, the mouthpiece may comprise a filter. In some implementations, the heat source may comprise an extruded monolithic carbonaceous material. In some implementations, the extruded monolithic carbonaceous material may define one or more grooves extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material.

In another implementation, the smoking article may comprise a heat source configured to generate heat upon ignition thereof, a substrate material having opposed first and second ends, the heat source being disposed proximate the first end of the substrate material, and the substrate material having an aerosol precursor composition associate therewith, a mouthpiece, the mouthpiece being disposed proximate the second end of the substrate material, and a heat transfer component located within the heat source. The heat transfer component may extend from the heat source and penetrate at least a portion of the substrate material, and the heat transfer component may include a cap located between the heat source and the substrate material. In some implementations, the heat transfer component may comprise one or more substantially close-ended structures. In some implementations, the one or more close-ended structures may be constructed of at least one of aluminum, and copper with an aluminum coating. In some implementations, the heat transfer component may comprise one or more substantially solid rods. In some implementations, the one or more substantially solid rods may be constructed of at least one of aluminum, and copper with an aluminum coating. In some implementations, the heat transfer component may comprise an aluminum mesh. In some implementations, the heat transfer component may further comprise an aluminum disc positioned at a location along a length of the aluminum mesh. In some implementations, the heat transfer component may comprise one or more substantially solid sheets. In some implementations, the one or more substantially solid sheets may be constructed of at least one of aluminum, and copper with an aluminum coating. In some implementations, the substrate material may comprise at least one of tobacco-containing beads, tobacco shreds, tobacco strips, pieces of a reconstituted tobacco material, or tobacco rods.

Some implementations may further comprise a liner configured to circumscribe the substrate material and at least a portion of the heat source. Some implementations may further comprise a second substrate material having opposed first and second ends, the second substrate material being disposed between the first substrate material and the mouthpiece. In some implementations, the second substrate material may comprise at least one of tobacco-containing beads, tobacco shreds, tobacco strips, pieces of a reconstituted tobacco material, or tobacco rods. In some implementations, the mouthpiece may comprise an intermediate component. In some implementations, the mouthpiece may comprise a filter. In some implementations, the heat source may comprise an extruded monolithic carbonaceous material. In some implementations, the extruded monolithic carbonaceous material may define one or more grooves extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material.

These and other features, aspects, and advantages of the disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter with reference to example embodiments thereof. These example embodiments are described 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 is 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 the specification, and in the appended claims, the singular forms “a”, “an”, “the”, include plural referents unless the context clearly dictates otherwise.

The present disclosure provides descriptions of articles (and the assembly and/or manufacture thereof) in which a material is heated (preferably without combusting the material to any significant degree) to form an aerosol and/or an inhalable substance; such articles most preferably being sufficiently compact to be considered “hand-held” devices. In preferred 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 (e.g., inhalation and exhalation rituals, types of tastes or flavors, organoleptic effects, physical feel, use rituals, visual cues such as those provided by visible aerosol, and the like) of smoking a cigarette, cigar, or pipe, without any substantial degree of combustion of any component of that article and/or device. As used herein, the term “smoking article” does not necessarily mean that, in operation, the article or device produces smoke in the sense of an aerosol resulting from by-products of combustion or pyrolysis of tobacco, but rather, that the article or device yields vapors (including vapors within aerosols that are considered to be visible aerosols that might be considered to be described as smoke-like) resulting from volatilization or vaporization of certain components, elements, and/or the like of the article and/or device. In preferred aspects, articles or devices characterized as smoking articles incorporate tobacco and/or components derived from tobacco.

Articles or devices of the present disclosure are also characterized as being vapor-producing articles, aerosol delivery articles, or medicament delivery articles. Thus, such articles or devices are adaptable so as to provide one or more substances in an inhalable form or state. For example, inhalable substances are substantially in the form of a vapor (e.g., a substance that is in the gas phase at a temperature lower than its critical point). Alternatively, inhalable substances are in the form of an aerosol (e.g., a suspension of fine solid particles or liquid droplets in a gas). For purposes of simplicity, the term “aerosol” as used herein is meant to include vapors, gases, and aerosols of a form or type suitable for human inhalation, whether or not visible, and whether or not of a form that might be considered to be smoke-like.

In use, smoking articles of the present disclosure are subjected to many of the physical actions of an individual in using a traditional type of smoking article (e.g., a cigarette, cigar, or pipe that is employed by lighting with a flame and used by inhaling tobacco that is subsequently burned and/or combusted). For example, the user of a smoking article of the present disclosure holds that article much like a traditional type of smoking article, draws on one end of that article for inhalation of an aerosol produced by that article, and takes puffs at selected intervals of time.

While the systems are generally described herein in terms of implementations associated with smoking articles such as so-called “e-cigarettes” or “tobacco heating products,” it should be understood that the mechanisms, components, features, and methods may be embodied in many different forms and associated with a variety of articles. For example, the description provided herein may be employed in conjunction with implementations of traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heat-not-burn cigarettes, and related packaging for any of the products disclosed herein. Accordingly, it should be understood that the description of the mechanisms, components, features, and methods disclosed herein are discussed in terms of implementations relating to aerosol delivery devices by way of example only, and may be embodied and used in various other products and methods.

Smoking articles of the present disclosure generally include a number of elements provided or contained within an enclosure of some sort, such as a housing, an outer wrap, or wrapping, a casing, a component, a module, a member, or the like. The overall design of the enclosure is variable, and the format or configuration of the enclosure that defines the overall size and shape of the smoking article is also variable. It is desirable, in some aspects, that the overall design, size, and/or shape of the enclosure resembles that of a conventional cigarette or cigar. Typically, an enclosure resembling the shape of a cigarette or cigar comprises three or more separable components, members, or the like that are engaged to form the enclosure. For example, such a smoking article may comprise, in some aspects, three separable components that include a mouthpiece component, an aerosol delivery component (such as, for example, a substrate material), and a heat source component. In various aspects, the heat source may be capable of generating heat to aerosolize a substrate material that comprises, for example, an extruded structure and/or substrate, a substrate material associated with an aerosol precursor composition, tobacco and/or a tobacco related material, such as a material that is found naturally in tobacco that is isolated directly from the tobacco or synthetically prepared, in a solid or liquid form (e.g., beads, sheets, shreds, a wrap), or the like. In some implementations, an extruded structure may comprise tobacco products or a composite of tobacco with other materials such as, for example, ceramic powder. In other implementations, a tobacco extract/slurry may be loaded into porous ceramic beads. Other implementations may use non-tobacco products. For example, in some implementations e-liquid-loaded porous beads/powders (ceramics) may be used. In other implementations, rods/cylinders made of extruded slurry of ceramic powder and e-liquid may be used.

According to certain aspects of the present disclosure, it may be advantageous to provide a smoking article that reduces carbon monoxide and/or carbon dioxide and/or other harmful products of carbon combustion, and/or provides improved heat transfer to the aerosol forming components.FIGS. 1 and 2illustrate perspective views of such a smoking article. In particular,FIG. 1illustrates a perspective view of a smoking article100that includes an outer wrap102, andFIG. 2illustrates the smoking article100wherein the outer wrap102and a liner118(described below) are removed to reveal the other components of the smoking article100. Referring toFIG. 2, (in addition to an outer wrap102and a liner118) the smoking article of the depicted implementation includes a heat source104, a heat transfer component105, a first inhalable substance medium106, a second inhalable substance medium108, an intermediate component110, and a filter112. In the depicted implementation, the intermediate component110and the filter112together comprise a mouthpiece114.

Although a smoking article according to the disclosure may take on a variety of implementations, as discussed in detail below, the use of the smoking article by a consumer will be similar in scope. The foregoing description of use of the smoking article is applicable to the various implementations described through minor modifications, which are apparent to the person of skill in the art in light of the further disclosure provided herein. The description of use, however, is not intended to limit the use of the inventive article but is provided to comply with all necessary requirements of disclosure herein.

In various implementations, the heat source104may be configured to generate heat upon ignition thereof. In the depicted implementation, the heat source104comprises a combustible fuel element that has a generally cylindrical shape and that incorporates a combustible carbonaceous material. In other implementations, the heat source104may have a different shape, for example, a prism shape having a cubic or hexagonal cross-section. Carbonaceous materials generally have a high carbon content. Preferred carbonaceous materials are composed predominately of carbon, and/or typically have carbon contents of greater than about 60 percent, generally 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 instances, the heat source104may incorporate elements other than combustible carbonaceous materials (e.g., tobacco components, such as powdered tobaccos or tobacco extracts; flavoring agents; salts, such as sodium chloride, potassium chloride and sodium carbonate; heat stable graphite fibers; iron oxide powder; glass filaments; powdered calcium carbonate; alumina granules; ammonia sources, such as ammonia salts; and/or binding agents, such as guar gum, ammonium alginate and sodium alginate). Although specific dimensions of an applicable heat source may vary, in the depicted implementation, the heat source104has a length in an inclusive range of approximately 7 mm to approximately 20 mm, and in some implementations may be approximately 17 mm, and an overall diameter in an inclusive range of approximately 3 mm to approximately 8 mm, and in some implementations may be approximately 4.8 mm (and in some implementations, approximately 7 mm). Although in other implementations, the heat source may be constructed in a variety of ways, in the depicted implementation, the heat source104is extruded or compounded using a ground or powdered carbonaceous material, and has a density that is greater than about 0.5 g/cm3, often greater than about 0.7 g/cm3, and frequently greater than about 1 g/cm3, on a dry weight basis. See, for example, the types of fuel source components, formulations and designs set forth 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. Although in various implementations, the heat source may have a variety of forms, including, for example, a substantially solid cylindrical shape or a hollow cylindrical (e.g., tube) shape, the heat source104of the depicted implementation comprises an extruded monolithic carbonaceous material that has a generally cylindrical shape but with a plurality of grooves116extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material. In the depicted implementation, the heat source104has a passageway117defined therethrough (seeFIG. 3). As will be discussed in more detail below, in various implementations, the passageway117is configured to receive a portion of the heat transfer component105.

Although in the depicted implementation, the grooves116of the heat source104are substantially equal in width and depth and are substantially equally distributed about a circumference of the heat source104, other implementations may include as few as two grooves, and still other implementations may include as few as a single groove. Still other implementations may include no grooves at all. Additional implementations may include multiple grooves that may be of unequal width and/or depth, and which may be unequally spaced around a 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 an opposing second end thereof. In some implementations, the heat source may comprise a foamed carbon monolith formed in a foam process of the type disclosed in U.S. Pat. No. 7,615,184 to Lobovsky, which is incorporated herein by reference in its entirety. As such, some implementations may provide advantages with regard to reduced time taken 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 expense. Other implementations of fuel elements include carbon fibers of the type described in U.S. Pat. No. 4,922,901 to Brooks et al. or other heat source implementations such as is disclosed in U.S. patent. App. Pub. No. 2009/0044818 to Takeuchi et al., each of which is incorporated herein by reference in its entirety.

Generally, the heat source is positioned sufficiently near an aerosol delivery component (e.g., a substrate material) having one or more aerosolizable components so that the aerosol formed/volatilized by the application of heat from the heat source to the aerosolizable components (as well as any flavorants, medicaments, and/or the like that are likewise provided for delivery to a user) is deliverable to the user by way of the mouthpiece. That is, when the heat source heats the substrate component, an aerosol is formed, released, or generated in a physical form suitable for inhalation by a consumer. It should be noted that the foregoing terms are meant to be interchangeable such that reference to release, releasing, releases, or released includes form or generate, forming or generating, forms or generates, and formed or generated. Specifically, an inhalable substance is released in the form of a vapor or aerosol or mixture thereof. Additionally, the selection of various smoking article elements are appreciated upon consideration of commercially available electronic smoking articles, such as those representative products listed in the background art section of the present disclosure.

FIG. 3illustrates a longitudinal cross-sectional schematic view of the smoking article100ofFIG. 1, according to one implementation of the present disclosure. In various implementations, the outer wrap102(shown most clearly inFIG. 1) is provided to engage or otherwise join together at least a portion of the heat source104with the first substrate material106, the second substrate material108, and at least a portion of the mouthpiece114. As such, the outer wrap material102is configured, in some aspects, to circumscribe, e.g., coaxially encircle, at least a portion of the heat source104, the first substrate material106engaged about the first end thereof with the heat source104, the second substrate material108engaged with the second end of the first substrate material106, and at least a portion of the mouthpiece114. The outer wrap102is configured to be retained in a wrapped position in any manner of ways including via an adhesive, or a fastener, and the like, to allow the outer wrap102to remain in the wrapped position. Otherwise, in some other aspects, the outer wrap102may be configured to be removable as desired. For example, upon retaining the outer wrap102in a wrapped position, the outer wrap102may be able to be removed from the heat source104, the first substrate material106engaged with the heat source104about the first end thereof, the second substrate material108engaged with the second end of the first substrate material106, and/or the mouthpiece114.

As shown in the figure, in addition to the outer wrap102, the depicted implementation also includes a liner118that is configured to circumscribe the first substrate material106and at least a portion of the heat source104. Although in other implementations the liner118may circumscribe only a portion of the length of the first substrate material106, in some implementations, the liner118may also circumscribe the second substrate material108. In some implementations, the outer wrap material102may include the liner118. As such, in some implementations the outer wrap material102and the liner118may be separate materials that are provided together (e.g., bonded, fused, or otherwise joined together as a laminate). In other implementations, the outer wrap102and the liner118may be the same material. In any event, the liner118may be configured to thermally regulate conduction of the heat generated by the ignited heat source104, radially outward of the liner118. As such, in some implementations, the liner118may be constructed of a metal foil material, a graphene material, a graphite material or other thermally conductive carbon-based material, and/or an aluminum material, and in some implementations may comprise a laminate. In the depicted implementation, the liner118is constructed of an aluminum laminate. In some implementations, depending on the material of the outer wrap102and/or the liner118, a thin layer of insulation may be provided radially outward of the liner118. Thus, the liner118may advantageously provide, in some aspects, a manner of engaging two or more separate components of the smoking article100(such as, for example, the heat source104and the first substrate material106), while also providing a manner of facilitating heat transfer axially therealong, but restricting radially outward heat conduction.

As also shown inFIG. 3, the outer wrap102(and, as necessary, the liner118, and the first substrate material106) may also include one or more openings120formed therethrough that allow the entry of air upon a draw on the mouthpiece114. In various implementations, the size and number of these openings may be tuned such that a larger fraction of the drawn airflow occurs through these openings (and, in some implementations, a higher air flowrate) and a smaller fraction of the airflow occurs through the hollow structure (and, in some implementations, a lower air flowrate) described below. In such a manner, the airflow through the hollow structure may be only, or mostly, for promoting the heat transfer. In some implementations, the openings120may be located between the distal end of the heat transfer component105and the first substrate material106. In some implementations, the openings120may be formed in the outer wrap102(and, in some implementations, the liner118) in an area proximate the first substrate material106, and one or more separate cooling openings121may be formed in the outer wrap102(and, in some implementations, the liner118) in an area proximate the filter112. In the depicted implementation, a plurality of substantially evenly spaced openings120are formed in the outer wrap102and liner118in an area proximate the first substrate material106, and a plurality of substantially evenly spaced separate cooling openings121are formed in the outer wrap102in an area proximate the mouthpiece114(e.g., proximate the filter112). Although in various implementations the plurality of openings may be formed through the outer wrap102(and the liner118) in a variety of ways, in the depicted implementation, the plurality of openings120and the plurality of separate cooling openings121are formed via laser perforation.

FIG. 4illustrates a perspective view of the heat source104and heat transfer component105of the smoking article100ofFIG. 1, according to one implementation of the present disclosure.FIG. 5illustrates a perspective view of the heat transfer component105of the smoking article100ofFIG. 1, according to one implementation of the present disclosure. In particular,FIG. 4illustrates that the heat transfer component105includes a hollow structure122with a first flange124located proximate one end thereof, and a second flange126located proximate a second end thereof. As illustrated inFIGS. 3 and 4, the heat source105is located between the first flange124and second flange126such that the hollow structure122of the heat transfer component105(seeFIG. 5) extends through the heat source104, and in particular, through the passageway117of the heat source104. Although in the depicted implementation, the hollow structure is shown in the form of a hollow tube, in other implementations, the hollow structure may have any other, non-cylinder hollow shapes. In the depicted implementation, the hollow structure122, the first flange124, and the second flange126of the heat transfer component105are constructed of aluminum. In other implementations, however, any one or any combination of these parts may be constructed of another heat conducting material, including, for example, stainless steel, brass, copper, silver, gold, bronze, graphite, ceramics (e.g., alumina, beryllia, boron nitride, aluminum nitride, silicon carbide, etc.), and/or combinations thereof. Moreover, any one or any combination of these parts may be constructed of one or more than one material (e.g., one conductive material) and coated with other materials (e.g., another conductive material).

In the depicted implementation, the first flange124and the second flange126are attached to the hollow structure122proximate respective ends thereof using a laser weld and/or brazing/soldering. In other implementations, however, other attachment and/or construction methods may be used. For example, in some implementations, the heat transfer component105may be constructed of a single part. In other implementations, one or more adhesives and/or other mechanical attachment means (e.g., a press fit or threaded engagement) may be used. In some implementations, the thickness of the flanges124,126may be in an inclusive range of approximately 0.05 mm to approximately 1 mm, and in some implementations may be approximately 0.1 mm-0.2 mm, the internal diameter of the hollow structure122may be in an inclusive range of approximately 0.1 mm to approximately 3 mm, and in some implementations may be approximately 0.3 mm-0.7 mm, and the hollow structure122wall thickness may be in an inclusive range of approximately 0.05 mm to approximately 1 mm, and in some implementations, may be approximately 0.1-0.2 mm. It should be noted that although the flanges of the depicted implementation have a substantially circular profile, in other implementations, one or both of the flanges may have other shapes, including, for example, substantially oval profiles and/or substantially polygonal profiles, such as, for example, triangular, rectangular, square, pentagonal, hexagonal, heptagonal, octagonal, etc. profiles.

In one implementation, the diameter (in other implementations, the overall size) of the first flange124may be approximately equal to the outer diameter of the heat source; however, in other implementations (such as the implementation depicted inFIG. 3) the diameter of the first flange122may be smaller than the outer diameter of the heat source104. As will be discussed below, such a configuration may promote air circulation in the grooves of the heat source104. In still other implementations, the diameter of the first flange122may be larger than the outer diameter of the heat source104. In various implementations, the diameter of the first flange124may be between ⅓ to 4/3 times of the diameter of the heat source104. In the depicted implementation, the diameter of the first flange124may be approximately ¾ times the diameter size of the heat source104. Although in some implementations, the diameter of the second flange126may vary, in the depicted implementation the diameter of the second flange126is approximately the same as the outer diameter of the heat source104. In addition, in various implementations the length of the hollow structure122may be at least as long as the length of the heat source104, and in some implementations, may extend into the first substrate material106(see e.g.,FIG. 11), and, in still other implementations, may further extend into the second substrate material108.

In various implementations, the hollow structure122of the heat transfer component may be open on its ends, such that air may flow through the hollow structure122. In such a manner, when a user takes a drag on the mouthpiece114of the smoking article100, air may travel through the heat transfer component105. In such a manner, air traveling through the hollow structure122may be in addition to air entering the smoking article100through the openings120formed through the outer wrap102(and, as necessary, the liner118) proximate the first substrate material106and the mouthpiece114. As such, in addition to the heat transfer functions provided by the structure of the heat transfer component105, wherein the heat transfer component105facilitates the transfer of heat from the heat source104to the first substrate material106through conduction (and/or subsequent substrate materials, such as, for example, the second substrate material108), the passage of air through the hollow structure122of the heat transfer component105during a drag on the smoking article100further facilitates transfer of heat from the heat source104to the first substrate material106(and/or subsequent substrate materials) through convection. It should be noted that in still other implementations, the hollow structure122connecting the first and second flanges124,126need not be hollow, and thus a solid connecting piece (e.g., a solid cylinder) may be used to connect the first and second flanges124,126. In such implementations, air would not pass through the heat transfer component.

In the depicted implementation, the smoking article100also includes a first substrate material106having opposed first and second ends, wherein the first end is disposed proximate the heat transfer component105. Although various implementations may only include one substrate material, in the depicted implementation, a second substrate material108is disposed proximate the second end of the first substrate material106. In other implementations, additional substrate materials may be included. In various implementations, one or more of the substrate materials may include a tobacco or tobacco related material, with an aerosol precursor composition associated therewith. Other possible compositions, components, and/or additives for use in a substrate material (and/or substrate materials) are described in more detail below. It should be noted that the subsequent discussion should be applicable any substrate material usable in the smoking articles described herein (such as, for example, the first substrate material106and/or the second substrate material108, individually or together).

In some implementations, the substrate material may comprise a blend of flavorful and aromatic tobaccos in cut filler form. In another implementation, the substrate material may comprise a reconstituted tobacco material, such as described in U.S. Pat. No. 4,807,809 to Pryor et al.; U.S. Pat. No. 4,889,143 to Pryor et al. and U.S. Pat. No. 5,025,814 to Raker, the disclosures of which are incorporated herein by reference in their entirety. Additionally, a reconstituted tobacco material may include a reconstituted tobacco paper for the type of cigarettes described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988), the contents of which are incorporated herein by reference in its entirety. For example, a reconstituted tobacco material may include a sheet-like material containing tobacco and/or tobacco-related materials.

As such, in some implementations, the substrate material may be formed from a wound roll of a reconstituted tobacco material. In another implementation, the substrate material may be formed from shreds, strips, and/or the like of a reconstituted tobacco material. In another implementation, the tobacco sheet may comprise overlapping layers (e.g., a gathered web), which may, or may not, include heat conducting constituents. Examples of substrate portions that include a series of overlapping layers (e.g., gathered webs) of an initial substrate sheet formed by the fibrous filler material, aerosol forming material, and plurality of heat conducting constituents are described in U.S. patent application Ser. No. 15/905,320, filed on Feb. 26, 2018, and titled Heat Conducting Substrate For Electrically Heated Aerosol Delivery Device, which is incorporated herein by reference in its entirety.

In some implementations, the substrate material may include a plurality of microcapsules, beads, granules, and/or the like having a tobacco-related material. For example, a representative microcapsule may be generally spherical in shape, and may have an outer cover or shell that contains a liquid center region of a tobacco-derived extract and/or the like. In some implementations, one or more of the substrate materials may include a plurality of microcapsules each formed into 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 into the hollow cylindrical shape.

In still other implementations of the present disclosure, the substrate material may be configured as an extruded structure that includes, or is essentially comprised of a tobacco, a tobacco related material, glycerin, water, and/or a binder material, although certain formulations may exclude the binder material. In various implementations, suitable binder materials may include alginates, such as ammonium alginate, propylene glycol alginate, potassium alginate, and sodium alginate. Alginates, and particularly high viscosity alginates, may be employed in conjunction with controlled levels of free calcium ions. Other suitable binder materials include hydroxypropylcellulose such as Klucel H from Aqualon Co.; hydroxypropylmethylcellulose such as Methocel K4MS from The Dow Chemical Co.; hydroxyethylcellulose such as Natrosol 250 MRCS from Aqualon Co.; 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 starches (e.g., corn starch), guar gum, carrageenan, locust bean gum, pectins and xanthan gum. In some implementations, combinations or blends of two or more binder materials may be employed. 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 a portion of the binder material (e.g., propylene glycol alginate). In addition, in some implementations, the binder material may comprise nanocellulose derived from a tobacco or other biomass.

In some implementations, the substrate material may be configured as an extruded material, as described in U.S. Pat. App. Pub. No. 2012/0042885 to Stone et al., which is incorporated herein by reference in its entirety. In yet another implementation, the substrate material 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. Pat. No. 5,105,831 to Banerjee, et al., which is incorporated by reference herein in its entirety. Marumarized tobacco includes about 20 to about 50 percent (by weight) tobacco blend in powder form, with glycerol (at about 20 to about 30 percent weight), calcium carbonate (generally at about 10 to about 60 percent by weight, often at about 40 to about 60 percent by weight), along with binder agents, as described herein, and/or flavoring agents. In various implementations, the extruded material may have one or more longitudinal openings.

In various implementations, the substrate material may take on a variety of conformations based upon the various amounts of materials utilized therein. For example, a sample substrate material may comprise up to approximately 98% by weight, up to approximately 95% by weight, or up to approximately 90% by weight of a tobacco and/or tobacco related material. A sample substrate material may also comprise up to approximately 25% by weight, approximately 20% by weight, or approximately 15% by weight water—particularly approximately 2% to approximately 25%, approximately 5% to approximately 20%, or approximately 7% to approximately 15% by weight water. Flavors and the like (which include, for example, medicaments, such as nicotine) may comprise up to approximately 10%, up to about 8%, or up to about 5% by weight of the aerosol delivery component.

Additionally or alternatively, the substrate material may be configured as an extruded structure and/or a substrate that includes or essentially is comprised of tobacco, glycerin, water, and/or binder material, and is further configured to substantially maintain its structure throughout the aerosol-generating process. That is, the substrate material may be configured to substantially maintain its shape (e.g., the substrate material does not continually deform under an applied shear stress) throughout the aerosol-generating process. Although such an example substrate material may include liquids and/or some moisture content, the substrate may remain substantially solid throughout the aerosol-generating process and may substantially maintain structural integrity throughout the aerosol-generating process. Example tobacco and/or tobacco related materials suitable for a substantially solid substrate material are described in U.S. Pat. App. Pub. No. 2015/0157052 to Ademe et al.; U.S. Pat. App. Pub. No. 2015/0335070 to Sears et al.; U.S. Pat. No. 6,204,287 to White; and U.S. Pat. No. 5,060,676 to Hearn et al., which are incorporated herein by reference in their entirety.

In some implementations, the amount of substrate material that is used within the smoking article may be such that the article exhibits acceptable sensory and organoleptic properties, and desirable performance characteristics. For example, in some implementations an aerosol precursor composition such as, for example, glycerin and/or propylene glycol, may be employed within the substrate material in order to provide for the generation of a visible mainstream aerosol that in many regards resembles the appearance of tobacco smoke. For example, the amount of aerosol precursor composition incorporated into the substrate material of the smoking article may be in the range of 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 gram or less.

According to another implementation, a smoking article according to the present disclosure may include a substrate material comprising a porous, inert material such as, for example, a ceramic material. For example, in some implementations ceramics of various shapes and geometries (e.g., beads, rods, tubes, etc.) may be used, which have various pore morphology. In addition, in some implementations non-tobacco materials, such as e-liquids, may be loaded into the ceramics. In another implementation, the substrate material may include a porous, inert material that does not substantially react, chemically and/or physically, with a tobacco-related material such as, for example, a tobacco-derived extract. In addition, an extruded tobacco, such as those described above, may be porous. For example, in some implementations an extruded tobacco material may have an inert gas, such as, for example, nitrogen, that acts as a blowing agent during the extrusion process.

As noted above, in various implementations one or more of the substrate materials may include a tobacco, a tobacco component, and/or a tobacco-derived material that has been treated, manufactured, produced, and/or processed to incorporate an aerosol precursor composition (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/burn retardant (e.g., diammonium phosphate and/or another salt) configured to help prevent ignition, pyrolysis, combustion, and/or scorching of the substrate material by the heat source. Various manners and methods for incorporating tobacco into smoking articles, and particularly smoking articles that are designed so as to not purposefully burn virtually all of the tobacco within those smoking articles are set forth 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. Pat. App. Pub. No. 2007/0215167 to Crooks et al.; the disclosures of which are incorporated herein by reference in their entireties.

As noted, in some implementations, flame/burn retardant materials and other additives that may be included within one or more of the substrate materials and may include organo-phosphorus compounds, borax, hydrated alumina, graphite, potassium tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Others such as nitrogenous phosphonic acid salts, mono-ammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ethanolammonium borate, ammonium sulphamate, halogenated organic compounds, thiourea, and antimony oxides are suitable but are not preferred agents. In each aspect of flame-retardant, burn-retardant, and/or scorch-retardant materials used in the substrate material and/or other components (whether alone or in combination with each other and/or other materials), the desirable properties most preferably are provided without undesirable off-gassing or melting-type behavior.

According other implementations of the present disclosure, the substrate material may also incorporate tobacco additives of the type that are traditionally used for the manufacture of tobacco products. Those additives may include the types of materials used to enhance the flavor and aroma of tobaccos used for the production of cigars, cigarettes, pipes, and the like. For example, those additives may include various cigarette casing and/or top dressing 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. Preferred casing materials may 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). Those added components may also include top dressing materials (e.g., flavoring materials, such as menthol). See, for example, U.S. Pat. No. 4,449,541 to Mays et al., the disclosure of which is incorporated herein by reference in its entirety. Further 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 disclosures of which are incorporated herein by reference in their entireties.

As noted above, in various implementations, one or more of the substrate materials may have an aerosol precursor composition associated therewith. For example, in some implementations the aerosol precursor composition may comprise one or more different components, such as polyhydric alcohol (e.g., glycerin, propylene glycol, or a mixture thereof). Representative types of further aerosol precursor compositions are set forth 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 WO 98/57556 to Biggs et al.; and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988); the disclosures of which are incorporated herein by reference. In some aspects, a substrate material may produce a visible aerosol upon the application of sufficient heat thereto (and cooling with air, if necessary), and the substrate material may produce an aerosol that is “smoke-like.” In other aspects, the substrate material may produce an aerosol that is substantially non-visible but is recognized as present by other characteristics, such as flavor or texture. Thus, the nature of the produced aerosol may be variable depending upon the specific components of the aerosol delivery component. The substrate material may be chemically simple relative to the chemical nature of the smoke produced by burning tobacco.

A wide variety of types of flavoring agents, or materials that alter the sensory or organoleptic character or nature of the mainstream aerosol of the smoking article may be suitable to be employed. In some implementations, such flavoring agents may be provided from sources other than tobacco and may be natural or artificial in nature. For example, some flavoring agents may be applied to, or incorporated within, the substrate material and/or those regions of the smoking article where an aerosol is generated. In some implementations, such agents may be supplied directly to a heating cavity or region proximate to the heat source or are provided with the substrate material. Example flavoring agents 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 flavorings and flavor packages of the type and character traditionally used for the flavoring of cigarette, cigar, and pipe tobaccos. Syrups, such as high fructose corn syrup, may also be suitable to be employed.

Flavoring agents may also include acidic or basic characteristics (e.g., organic acids, such as levulinic acid, succinic acid, and pyruvic acid). In some implementations, flavoring agents may be combinable with the elements of the substrate material if desired. Example plant-derived compositions that may be suitable are disclosed in U.S. Pat. No. 9,107,453 and U.S. Pat. App. Pub. 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, casings, and the like that may be useful in combination with a tobacco material to affect sensory properties thereof, including organoleptic properties, such as described herein, may be combined with the substrate material. Organic acids particularly may be able to be incorporated into the substrate material to affect the flavor, sensation, or organoleptic properties of medicaments, such as nicotine, that may be able to 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 with nicotine in amounts up to being equimolar (based on total organic acid content) with the nicotine. Any combination of organic acids may be suitable. For example, in some implementations, the substrate material may include approximately 0.1 to about 0.5 moles of levulinic acid per one mole of nicotine, approximately 0.1 to about 0.5 moles of pyruvic acid per one mole of nicotine, approximately 0.1 to about 0.5 moles of lactic acid per one mole of nicotine, or combinations thereof, up to a concentration wherein the total amount of organic acid present is equimolar to the total amount of nicotine present in the substrate material. Various additional examples of organic acids employed to produce a substrate material are described in U.S. Pat. App. Pub. No. 2015/0344456 to Dull et al., which is incorporated herein by reference in its entirety.

The selection of such further components may be variable based upon factors such as the sensory characteristics that are desired for the smoking article, and the present disclosure is intended to encompass any such further components that are 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 entireties.

In other implementations, the first substrate material may include other materials having a variety of inherent characteristics or properties. For example, the substrate material may include a plasticized material or regenerated cellulose in the form of rayon. As another example, viscose (commercially available as VISIL®), which is a regenerated cellulose product incorporating silica, may be suitable. Some carbon fibers may include at least 95 percent carbon or more. Similarly, natural cellulose fibers such as cotton may be suitable, and may be infused or otherwise treated with silica, carbon, or metallic particles to enhance flame-retardant properties and minimize off-gassing, particularly of any undesirable off-gassing components that would have a negative impact on flavor (and especially minimizing the likelihood of any toxic off-gassing products). Cotton may be treatable with, for example, boric acid or various organophosphate compounds to provide desirable flame-retardant properties by dipping, spraying or other techniques known in the art. These fibers may also be treatable (coated, infused, or both by, e.g., dipping, spraying, or vapor-deposition) with organic or metallic nanoparticles to confer the desired property of flame-retardancy without undesirable off-gassing or melting-type behavior.

Referring back toFIGS. 1 and 2, in the smoking article100of the depicted implementation, the first substrate material106comprises a plurality of tobacco beads formed into a substantially cylindrical portion. Although, as noted above, in various implementations the size and shape of the first substrate material may vary, for example in some implementations the first substrate material106may have a length in an inclusive range of approximately 5 mm to approximately 15 mm, and an overall diameter in an inclusive range of approximately 3 mm to approximately 8 mm, in the depicted implementation the first substrate material106has a length of approximately 10 mm and a diameter of approximately 4.8 mm (and in some implementations, approximately 7 mm). In the depicted implementation the second substrate material108comprises a plurality of tobacco rods formed into a substantially cylindrical portion Likewise, although in various implementations the size and shape of the second substrate material108may vary, for example in some implementations the second substrate material108may have a length in an inclusive range of approximately 5 mm to approximately 25 mm, and an overall diameter in an inclusive range of approximately 3 mm to approximately 8 mm, in the depicted implementation the second substrate material108has a length of approximately 10 mm and a diameter of approximately 4.8 mm (and in some implementations, approximately 7 mm).

In the depicted implementation, the first and second substrate materials106,108may comprise centrally defined longitudinally extending axes between each of the respective opposed first and second ends, and a cross-section of the first and second substrate materials106,108may be, in some implementations, symmetrical about the axis. For example, in some implementations cross-sections of the first substrate material106and the second substrate material108may be substantially circular such that the first and second substrate materials106,108define substantially cylindrical shapes extending between the opposed first and second ends thereof. However, in other implementations, the first and second substrate materials106,108may define substantially non-circular cross-sections such that one or both of the first substrate material106or the second substrate material108may define a substantially non-cylindrical shape between the opposed first and second ends thereof. Otherwise, in other examples, one or both of the first substrate material106or the second substrate material108may comprise an asymmetric cross-section about the axis. In various implementations, each end of the first and second substrate materials,106,108may be in axial alignment with adjacent elements. For example, the first end of the second substrate material108may be configured to be in coaxial alignment with the second end of the first substrate material106upon engagement therebetween.

The smoking article of the depicted implementation also includes an intermediate component110and at least one filter112. It should be noted that in various implementations, the intermediate component110or the filter112, individually or together, may be considered a mouthpiece114of the smoking article100. Although in various implementations, neither the intermediate component nor the filter need be included, in the depicted implementation the intermediate component110comprises a substantially rigid member that is substantially inflexible along its longitudinal axis. In the depicted implementation, the intermediate component110comprises a hollow tube structure, and is included to add structural integrity to the smoking article100and provide for cooling the produced aerosol. In some implementations, the intermediate component110may be used as a container for collecting the aerosol. In the depicted implementation, the filter112is included to filter the aerosol generated by the substrate materials106and/or108before being inhaled by a user. In various implementations, such a tube may be constructed from any of a variety of materials and may include one or more adhesives. Example materials include, but are not limited to, paper, paper layers, paperboard, plastic, cardboard, and/or composite materials. In the depicted implementation, the intermediate component110comprises a hollow cylindrical element constructed of a paper or plastic material (such as, for example, ethyl vinyl acetate (EVA), or other polymeric materials such as poly ethylene, polyester, silicone, etc. or ceramics (e.g., silicon carbide, alumina, etc.), or other acetate fibers), and the filter comprises a packed rod or cylindrical disc constructed of a gas permeable material (such as, for example, cellulose acetate or fibers such as paper or rayon, or polyester fibers). The filter112may additionally or alternatively contain strands of tobacco containing material, such as described in U.S. Pat. No. 5,025,814 to Raker et al., which is incorporated herein by reference in its entirety. In various implementations the size and shape of the intermediate component110and/or the filter112may vary, for example the length of the intermediate component110may be in an inclusive range of approximately 10 mm to approximately 30 mm, the diameter of the intermediate component110may be in an inclusive range of approximately 3 mm to approximately 8 mm, the length of the filter112may be in an inclusive range of approximately 10 mm to approximately 20 mm, and the diameter of the filter112may be in an inclusive range of approximately 3 mm to approximately 8 mm. In the depicted implementation, the intermediate component110has a length of approximately 20 mm and a diameter of approximately 4.8 mm (and in some implementations, approximately 7 mm), and the filter112has a length of approximately 15 mm and a diameter of approximately 4.8 mm (or in some implementations, approximately 7 mm).

In various implementations, the mouthpiece114(e.g., the intermediate component110and/or the filter112) is configured to receive the generated aerosol therethrough in response to a draw applied to the mouthpiece114by a user. In some implementations, the mouthpiece114may be fixedly engaged to the substrate material (such as substrate material108). For example, an adhesive, a bond, a weld, and the like may be suitable for fixedly engaging the mouthpiece114to the substrate material108. In one example, the mouthpiece114is ultrasonically welded and sealed to the second end of the substrate material108.

As noted, in some implementations the mouthpiece114may comprise a filter112configured to receive the aerosol therethrough in response to the draw applied to the mouthpiece114. In various implementations, the filter112is provided, in some aspects, as a circular disc radially and/or longitudinally disposed proximate the second end of the intermediate component108. In this manner, upon draw on the mouthpiece114, the filter112receives the aerosol flowing through the intermediate component110of the smoking article100.

In various implementations, ignition of the heat source104results in aerosolization of the aerosol precursor composition associated with the first substrate material106and the second substrate material108. Preferably, the elements of the first substrate material106and the second substrate material108do not experience thermal decomposition (e.g., charring, scorching, or burning) to any significant degree, and the aerosolized components are entrained in the air that is drawn through the smoking article100, including the filter112, and into the mouth of the user.

FIG. 6illustrates a longitudinal cross-sectional schematic view of a smoking article200, according to another implementation of the present disclosure. In particular,FIG. 6illustrates a smoking article200that includes an outer wrap202, a heat source204, a heat transfer component205, a first inhalable substance medium206, a second inhalable substance medium208, and a filter212, which may comprise a mouthpiece214.

In various implementations, the heat source204may be configured to generate heat upon ignition thereof. In the depicted implementation, the heat source204comprises a combustible fuel element that has a generally cylindrical shape and that incorporates a combustible carbonaceous material. Carbonaceous materials generally have a high carbon content. Preferred carbonaceous materials are composed predominately of carbon, and/or typically have carbon contents of greater than about 60 percent, generally 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 instances, the heat source204may incorporate elements other than combustible carbonaceous materials (e.g., tobacco components, such as powdered tobaccos or tobacco extracts; flavoring agents; salts, such as sodium chloride, potassium chloride and sodium carbonate; heat stable graphite fibers; iron oxide powder; glass filaments; powdered calcium carbonate; alumina granules; ammonia sources, such as ammonia salts; and/or binding agents, such as guar gum, ammonium alginate and sodium alginate). Although specific dimensions of an applicable heat source may vary, in the depicted implementation, the heat source204has a length in an inclusive range of approximately 7 mm to approximately 20 mm, and in some implementations may be approximately 17 mm, and an overall diameter in an inclusive range of approximately 3 mm to approximately 8 mm, and in some implementations may be approximately 4.8 mm (and in some implementations, approximately 7 mm). Although in other implementations, the heat source may be constructed in a variety of ways, in the depicted implementation, the heat source204is extruded or compounded using a ground or powdered carbonaceous material, and has a density that is greater than about 0.5 g/cm3, often greater than about 0.7 g/cm3, and frequently greater than about 1 g/cm3, on a dry weight basis. See, for example, the types of fuel source components, formulations and designs set forth 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.

Although in various implementations, the heat source may have a variety of forms, including, for example, a substantially solid cylindrical shape or a hollow cylindrical (e.g., tube) shape, the heat source204of the depicted implementation comprises an extruded monolithic carbonaceous material defining a plurality of grooves (not visible inFIG. 6) extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material. Although in the depicted implementation, the grooves are substantially equal in width and depth and are substantially equally distributed about the circumference of the heat source204, other implementations may include a single groove. Other implementations may include multiple grooves that may be of unequal width and/or depth, and which may be unequally 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 an opposing second end thereof. In some implementations, the heat source may comprise a foamed carbon monolith formed in a foam process of the type disclosed in U.S. Pat. No. 7,615,184 to Lobovsky, which is incorporated herein by reference in its entirety. As such, some implementations may provide advantages with regard to reduced time taken to ignite the heat source. In another implementation, the heat source may be co-extruded with a layer of insulation (not shown), thereby reducing manufacturing time and expense. Other implementations of fuel elements include carbon fibers of the type described in U.S. Pat. No. 4,922,901 to Brooks et al. or other heat source embodiments such as is disclosed in U.S. Pat. App. Pub. No. 2009/0044818 to Takeuchi et al., each of which is incorporated herein by reference in its entirety.

Generally, the heat source is positioned sufficiently near a substrate material having one or more aerosolizable components so that the aerosol formed/volatilized by the application of heat from the heat source to the substrate material (as well as one or more flavorants, medicaments, or the like that are likewise provided for delivery to a user) is deliverable to the user by way of 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 a consumer. It should be noted that the foregoing terms are meant to be interchangeable such that reference to release, releasing, releases, or released includes form or generate, forming or generating, forms or generates, and formed or generated. Specifically, an inhalable substance is released in the form of a vapor or aerosol or mixture thereof. Additionally, the selection of various smoking article elements are appreciated upon consideration of commercially available electronic smoking articles, such as those representative products listed in the background art section of the present disclosure.

In the depicted implementation, the heat transfer component205comprises a hollow cylindrical tube having one or both ends closed and that extends through a portion of the heat source204and penetrates into a portion of the first substrate material206. It should be noted that in other implementations, the heat transfer component may comprise a solid rod (such as the heat transfer component275shown inFIG. 7). In various implementations, the heat transfer component may extend through any portion of the heat source204and may penetrate any portion of a substrate material. In some implementations, the heat transfer component205may further extend into a portion of a second substrate material208. In the depicted implementation, the heat transfer component205extends through substantially the full length of the heat source204and penetrates substantially the full length of the first substrate material206.

In the depicted implementation, the heat transfer component205is constructed of a copper material coated with an aluminum material. In other implementations, however, the heat transfer component may be constructed of other heat conducting materials, including, for example, stainless steel, brass, copper, aluminum, silver, gold, bronze, graphite, with or without a coating, and combinations thereof. Moreover, any one or any combination of these parts may be constructed of one material (e.g., one conductive material) and coated with another material (e.g., another conductive material). In the depicted implementation, the heat transfer component has a diameter in an inclusive range of approximately 1 mm to approximately 3 mm, an internal diameter in an inclusive range of approximately 0.5 mm to approximately 2.5 mm, and a length in an inclusive range of approximately 10 mm to approximately 35 mm. In such a manner, the heat transfer component205facilitates transfer of heat from the heat source204to the first substrate material206(and, in some implementations, additional substrate materials).

In the depicted implementation, the smoking article200also includes a first substrate material206having opposed first and second ends, wherein the first end is disposed proximate the heat transfer component205. Although various implementations may include only one substrate material, in the depicted implementation, a second substrate material208is disposed proximate the second end of the first substrate material206. In other implementations, additional substrate materials may be included. In various implementations, one or more of the substrate materials may include a tobacco or tobacco related material, with an aerosol precursor composition associated therewith. Other possible compositions, components, and/or additives for use in the first substrate material and/or the second substrate material and/or any other substrate materials are described in more detail below.

In some implementations, the substrate material may comprise a blend of flavorful and aromatic tobaccos in cut filler form. In another implementation, the substrate material may comprise a reconstituted tobacco material, such as described in U.S. Pat. No. 4,807,809 to Pryor et al.; U.S. Pat. No. 4,889,143 to Pryor et al. and U.S. Pat. No. 5,025,814 to Raker, the disclosures of which are incorporated herein by reference in their entirety. Additionally, a reconstituted tobacco material may include a reconstituted tobacco paper for the type of cigarettes described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988), the contents of which are incorporated herein by reference in its entirety. For example, a reconstituted tobacco material may include a sheet-like material containing tobacco and/or tobacco-related materials.

As such, in some implementations, the substrate material may be formed from a wound roll of a reconstituted tobacco material. In another implementation, the substrate material may be formed from shreds, strips, and/or the like of a reconstituted tobacco material.

In some implementations, the substrate material may include a plurality of microcapsules, beads, granules, and/or the like having a tobacco-related material. For example, a representative microcapsule may be generally spherical in shape, and may have an outer cover or shell that contains a liquid center region of a tobacco-derived extract and/or the like. In some implementations, one or more of the substrate materials may include a plurality of microcapsules each formed into 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 into the hollow cylindrical shape.

In still another aspect of the present disclosure, the substrate material may be configured as an extruded structure that includes, or is essentially comprised of a tobacco, a tobacco related material, glycerin, water, and/or a binder material, although certain formulations exclude the binder material. The binder material may be any binder material commonly used for tobacco formulations including, for example, carboxymethyl cellulose (CMC), gum (e.g. guar gum), xanthan, pullulan, and/or an alginate. According to some aspects, the binder material included in the substrate material may be configured to substantially maintain a structural shape and/or integrity of the substrate material. Various representative binders, binder properties, usages of binders, and amounts of binders are set forth in U.S. Pat. No. 4,924,887 to Raker et al., which is incorporated herein by reference in its entirety.

In some implementations, the substrate material may be configured as an extruded material, as described in U.S. Pat. App. Pub. No. 2012/0042885 to Stone et al., which is incorporated herein by reference in its entirety. In yet another implementation, the substrate material 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. Pat. No. 5,105,831 to Banerjee, et al., which is incorporated by reference herein in its entirety. Marumarized tobacco includes about 20 to about 50 percent (by weight) tobacco blend in powder form, with glycerol (at about 20 to about 30 percent weight), calcium carbonate (generally at about 10 to about 60 percent by weight, often at about 40 to about 60 percent by weight), along with binder agents, as described herein, and/or flavoring agents.

In various implementations, the substrate material may take on a variety of conformations based upon the various amounts of materials utilized therein. For example, a sample substrate material may comprise up to approximately 98% by weight, up to approximately 95% by weight, or up to approximately 90% by weight of a tobacco and/or tobacco related material. A sample substrate material may also comprise up to approximately 25% by weight, approximately 20% by weight, or approximately 15% by weight water—particularly approximately 2% to approximately 25%, approximately 5% to approximately 20%, or approximately 7% to approximately 15% by weight water. Flavors and the like (which include, for example, medicaments, such as nicotine) may comprise up to approximately 10%, up to about 8%, or up to about 5% by weight of the aerosol delivery component.

Additionally or alternatively, the substrate material may be configured as an extruded structure and/or a substrate that includes or essentially is comprised of tobacco, glycerin, water, and/or binder material, and is further configured to substantially maintain its structure throughout the aerosol-generating process. That is, the substrate material may be configured to substantially maintain its shape (e.g., the substrate material does not continually deform under an applied shear stress) throughout the aerosol-generating process. Although such an example substrate material may include liquids and/or some moisture content, the substrate may remain substantially solid throughout the aerosol-generating process and may substantially maintain structural integrity throughout the aerosol-generating process. Example tobacco and/or tobacco related materials suitable for a substantially solid substrate material are described in U.S. Pat. App. Pub. No. 2015/0157052 to Ademe et al.; U.S. Pat. App. Pub. No. 2015/0335070 to Sears et al.; U.S. Pat. No. 6,204,287 to White; and U.S. Pat. No. 5,060,676 to Hearn et al., which are incorporated herein by reference in their entirety.

In some implementations, the amount of substrate material that is used within the smoking article may be such that the article exhibits acceptable sensory and organoleptic properties, and desirable performance characteristics. For example, in some implementations sufficient aerosol precursor composition such as, for example, glycerin and/or propylene glycol, may be employed within the substrate material in order to provide for the generation of a visible mainstream aerosol that in many regards resembles the appearance of tobacco smoke. For example, the amount of aerosol precursor composition incorporated into the substrate material of the smoking article may be in the range of 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 gram or less.

According to another implementation, a smoking article according to the present disclosure includes a substrate material comprising a porous, inert material such as, for example, a ceramic material. In another aspect, the aerosol delivery component includes a porous, inert material that does not substantially react, chemically and/or physically, with a tobacco-related material such as, for example, a tobacco-derived extract.

As noted above, in various implementations one or more of the substrate materials may include a tobacco, a tobacco component, and/or a tobacco-derived material that has been treated, manufactured, produced, and/or processed to incorporate an aerosol precursor composition (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 burn retardant (e.g., diammonium phosphate and/or another salt) configured to help prevent ignition, pyrolysis, combustion, and/or scorching of the aerosol delivery component by the heat source. Various manners and methods for incorporating tobacco into smoking articles, and particularly smoking articles that are designed so as to not purposefully burn virtually all of the tobacco within those smoking articles are set forth 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. Pat. App. Pub. No. 2007/0215167 to Crooks et al.; the disclosures of which are incorporated herein by reference in their entireties.

In some implementations, flame/burn retardant materials and other additives that may be included within one or more of the substrate materials may include organo-phosphorus compounds, borax, hydrated alumina, graphite, potassium tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Others such as nitrogenous phosphonic acid salts, mono-ammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ethanolammonium borate, ammonium sulphamate, halogenated organic compounds, thiourea, and antimony oxides are suitable but are not preferred agents. In each aspect of flame-retardant, burn-retardant, and/or scorch-retardant materials used in the aerosol delivery component and/or other components (whether alone or in combination with each other and/or other materials), the desirable properties most preferably are provided without undesirable off-gassing or melting-type behavior.

According other implementations of the present disclosure, the substrate material may also incorporate tobacco additives of the type that are traditionally used for the manufacture of tobacco products. Those additives may include the types of materials used to enhance the flavor and aroma of tobaccos used for the production of cigars, cigarettes, pipes, and the like. For example, those additives may include various cigarette casing and/or top dressing 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. Preferred casing materials may 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). Those added components may also include top dressing materials (e.g., flavoring materials, such as menthol). See, for example, U.S. Pat. No. 4,449,541 to Mays et al., the disclosure of which is incorporated herein by reference in its entirety. Further 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 disclosures of which are incorporated herein by reference in their entireties.

As noted above, in various implementations, one or more of the substrate materials may have an aerosol precursor composition associated therewith. For example, in some implementations the aerosol precursor composition may comprise one or more different components, such as polyhydric alcohol (e.g., glycerin, propylene glycol, or a mixture thereof). Representative types of further aerosol precursor compositions are set forth 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 WO 98/57556 to Biggs et al.; and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988); the disclosures of which are incorporated herein by reference. In some aspects, an aerosol delivery component may produce a visible aerosol upon the application of sufficient heat thereto (and cooling with air, if necessary), and the aerosol delivery component may produce an aerosol that is “smoke-like.” In other aspects, the aerosol delivery component may produce an aerosol that is substantially non-visible but is recognized as present by other characteristics, such as flavor or texture. Thus, the nature of the produced aerosol may be variable depending upon the specific components of the aerosol delivery component. The aerosol delivery component may be chemically simple relative to the chemical nature of the smoke produced by burning tobacco.

A wide variety of types of flavoring agents, or materials that alter the sensory or organoleptic character or nature of the mainstream aerosol of the smoking article may be suitable to be employed. In some implementations, such flavoring agents may be provided from sources other than tobacco and may be natural or artificial in nature. For example, some flavoring agents may be applied to, or incorporated within, the substrate material and/or those regions of the smoking article where an aerosol is generated. In some implementations, such agents may be supplied directly to a heating cavity or region proximate to the heat source or are provided with the substrate material. Example flavoring agents 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 flavorings and flavor packages of the type and character traditionally used for the flavoring of cigarette, cigar, and pipe tobaccos. Syrups, such as high fructose corn syrup, may also be suitable to be employed.

Flavoring agents may also include acidic or basic characteristics (e.g., organic acids, such as levulinic acid, succinic acid, and pyruvic acid). In some implementations, flavoring agents may be combinable with the elements of the substrate material if desired. Example plant-derived compositions that may be suitable are disclosed in U.S. Pat. No. 9,107,453 and U.S. Pat. App. Pub. 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, casings, and the like that may be useful in combination with a tobacco material to affect sensory properties thereof, including organoleptic properties, such as described herein, may be combined with the substrate material. Organic acids particularly may be able to be incorporated into the substrate material to affect the flavor, sensation, or organoleptic properties of medicaments, such as nicotine, that may be able to 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 with nicotine in amounts up to being equimolar (based on total organic acid content) with the nicotine. Any combination of organic acids may be suitable. For example, in some implementations, the substrate material may include approximately 0.1 to about 0.5 moles of levulinic acid per one mole of nicotine, approximately 0.1 to about 0.5 moles of pyruvic acid per one mole of nicotine, approximately 0.1 to about 0.5 moles of lactic acid per one mole of nicotine, or combinations thereof, up to a concentration wherein the total amount of organic acid present is equimolar to the total amount of nicotine present in the substrate material. Various additional examples of organic acids employed to produce an aerosol delivery component are described in U.S. Pat. App. Pub. No. 2015/0344456 to Dull et al., which is incorporated herein by reference in its entirety.

The selection of such further components may be variable based upon factors such as the sensory characteristics that are desired for the smoking article, and the present disclosure is intended to encompass any such further components that are 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 entireties.

In other implementations, the first substrate material206may include other materials having a variety of inherent characteristics or properties. For example, the first substrate material206may comprise a plasticized material or regenerated cellulose in the form of rayon. As another example, viscose (commercially available as VISIL®), which is a regenerated cellulose product incorporating silica, may be suitable. Some carbon fibers may include at least 95 percent carbon or more. Similarly, natural cellulose fibers such as cotton may be suitable, and may be infused or otherwise treated with silica, carbon, or metallic particles to enhance flame-retardant properties and minimize off-gassing, particularly of any undesirable off-gassing components that would have a negative impact on flavor (and especially minimizing the likelihood of any toxic off-gassing products). Cotton may be treatable with, for example, boric acid or various organophosphate compounds to provide desirable flame-retardant properties by dipping, spraying or other techniques known in the art. These fibers may also be treatable (coated, infused, or both by, e.g., dipping, spraying, or vapor-deposition) with organic or metallic nanoparticles to confer the desired property of flame-retardancy without undesirable off-gassing or melting-type behavior.

The smoking article200of the depicted implementation also includes a heat transfer cap207that is configured to cover an end of the heat source204proximate the first substrate material106. In some implementations, the cap207may be pressed onto the end of the heat source204. In the depicted implementation, the heat transfer cap207includes an end portion207A that covers substantially the entire end of the heat source204proximate the first substrate material206, and a rim portion207B that extends upward and peripherally around at least a portion of the length of the heat source204. In the depicted implementation, the rim portion207B of the heat transfer cap207extends approximately ⅓ to ½ of the length of the heat source204. In the depicted implementation, the heat transfer cap207is constructed of the same material as the heat transfer component205. However, in other implementations, one or both the heat transfer component505or the heat transfer cap507may be constructed of another material, as described herein. In addition, in various implementations, one or both the heat transfer component205or the heat transfer cap207may be constructed of one material (e.g., one conductive material) and coated with another material (e.g., another conductive material).

In the depicted implementation, the heat transfer component205extends through a portion of the heat source204and penetrates into a portion of the first substrate material206, and in particular, substantially the entire length of the first substrate material206. However, in other implementations, the heat transfer component205may extend through any portion of the heat source204and may penetrate any portion of a first substrate material, and, in some implementations, may further extend into a portion of a second substrate material.

As noted above, in some implementations, the smoking article200may further comprise a second substrate material208having opposed first and second ends. In various implementations, the second substrate material208may comprise a centrally defined longitudinally extending axis between each of the opposed first and second ends. Like the first substrate material206in some implementations, a cross-section of the second substrate material208may be, in some implementations, symmetrical about the axis. For example, in some implementations cross-sections of the first substrate material206and the second substrate material208may be substantially circular such that the first and second substrate materials206,208define substantially cylindrical shapes extending between the opposed first and second ends thereof. However, in other implementations, the first and second substrate materials206,208may define substantially non-circular cross-sections such that one or both of the first substrate material206or the second substrate material208may define a substantially non-cylindrical shape between the opposed first and second ends thereof. Otherwise, in other examples, one or both of the first substrate material206or the second substrate material208may comprise an asymmetric cross-section about the axis. In various implementations, each end of the first and second substrate materials,206,208may be axial alignment with adjacent elements. For example, the first end of the second substrate material208may be configured to be in coaxial alignment with the second end of the first substrate material206upon engagement therebetween.

In various implementations, ignition of the heat source204results in aerosolization of the aerosol precursor composition associated with each of the first substrate material206and the second substrate material208. Preferably, the elements of the first substrate material206and the second substrate material208do not experience thermal decomposition (e.g., charring, scorching, or burning) to any significant degree, and the aerosolized components are entrained in the air that is drawn through the smoking article200, including the filter212, and into the mouth of the user.

Referring back toFIG. 6, the outer wrap202is provided to engage or otherwise join together at least a portion of the heat source204with the first substrate material206, the second substrate material208, and at least a portion of the mouthpiece214. As such, the outer wrap material202is configured, in some aspects, to circumscribe, e.g., coaxially encircle, at least a portion of the heat source204, the first substrate material206engaged about the first end thereof with the heat source204, the second substrate material208engaged with the second end of the first substrate material206, and at least a portion of the mouthpiece214. The outer wrap202is configured to be retained in a wrapped position in any manner of ways including via an adhesive, or a fastener, and the like, to allow the outer wrap202to remain in the wrapped position. Otherwise, in some other aspects, the outer wrap202may be configured to be removable as desired. For example, upon retaining the outer wrap202in a wrapped position, the outer wrap202may be able to be removed from the heat source204, the first substrate material206engaged with the heat source204about the first end thereof, the second substrate material208engaged with the second end of the first substrate material206, and a portion of the mouthpiece214. In this example, the adhesive, fastener, or the like is removed and the outer wrap material202is uncircumscribed thereabout.

As shown in the figure, in addition to the outer wrap202, the depicted implementation also includes a liner218that is configured to circumscribe the first substrate material206and at least a portion of the heat source204. In some implementations, the liner218may also circumscribe the second substrate material208. In some implementations, the outer wrap material202may include the liner218. As such, in some implementations the outer wrap material202and the liner218may be separate materials that are provided together (e.g., bonded, fused, or otherwise joined together as a laminate). In other instances, the outer wrap202and the liner218may be the same material. In any event, the liner218may be configured to thermally regulate conduction of the heat generated by the ignited heat source204, radially outward of the liner218. As such, in some implementations, the liner218may be constructed of a foil material, a graphene material, a graphite material, and/or an aluminum material, and in any event, the material may be laminate. In the depicted implementations, the liner is constructed of an aluminum laminate. In some implementations, depending on the material of the outer wrap202and/or the liner218, a thin layer of insulation may be provided radially outward of the liner218. Thus, the liner218advantageously provides, in some aspects, a manner of engaging two or more separate components of the smoking article200(such as, for example, the heat source204and the first substrate material206), while also providing a manner of facilitating heat transfer axially therealong, but restricting radially outward heat conduction.

As also shown inFIG. 6, the outer wrap202(and, as necessary, the liner218, and the first substrate material206) may also include one or more openings220formed therethrough that allow the entry of air upon a draw on the mouthpiece214. In some implementations, the openings220may be located between the distal end of the heat transfer component205and the first substrate material206. In some implementations, the openings220may be formed in the outer wrap202(and, in some implementations, the liner218) in an area proximate the first substrate material206, and separate cooling openings221may be formed in the outer wrap202(and, in some implementations, the liner218) in an area proximate the filter212. In the depicted implementation, a plurality of substantially evenly spaced openings220are formed in the outer wrap202and liner218in an area proximate the first substrate material206, and a plurality of substantially even spaced separate cooling openings221are formed in the outer wrap202in an area proximate the mouthpiece214(e.g., in the depicted implementation, proximate the filter212). Although in various implementations the openings may be formed through the outer wrap202(and the liner218) in a variety of ways, in the depicted implementation, the plurality of openings220are formed via laser perforation.

In the smoking article200of the depicted implementation, the first substrate material206comprises a plurality of tobacco beads formed into a substantially cylindrical portion. Although, as noted above, in various implementations the size and shape of the first substrate material may vary, for example the first substrate material206may have a length in an inclusive range of approximately 5 mm to approximately 15 mm, and an overall diameter in an inclusive range of approximately 3 mm to approximately 8 mm, in the depicted implementation the first substrate material has a length of approximately 10 mm and a diameter of approximately 4.8 mm (and in some implementations, approximately 7 mm). In the depicted implementation the second substrate material208comprises a plurality of tobacco rods formed into a substantially cylindrical portion. Likewise, although in various implementations the size and shape of the second substrate material108may vary, for example in some implementations the second substrate material208may have a length in an inclusive range of approximately 5 mm to approximately 25 mm, and an overall diameter in an inclusive range of approximately 3 mm to approximately 8 mm, in the depicted implementation the second substrate material208has a length of approximately 30 mm and a diameter of approximately 4.8 mm (and in some implementations, approximately 7 mm).

The smoking article of the depicted implementation also includes a filter212. It should be noted that in various implementations, the smoking article may also include an intermediate component, such as the intermediate component described above. In various implementations, the filter212, individually or together with another component, may be considered a mouthpiece214of the smoking article200. It should be noted that in various implementations, neither the intermediate component nor the filter need be included. In the depicted implementation, however, the filter212is included to filter the aerosol generated by the substrate materials206and/or208before being inhaled by a user. In the depicted implementation, the filter comprises a packed rod or cylindrical disc constructed of a gas permeable material (such as, for example, cellulose acetate or fibers such as paper or rayon, or polyester fibers). The filter112may additionally or alternatively contain strands of tobacco containing material, such as described in U.S. Pat. No. 5,025,814 to Raker et al., which is incorporated herein by reference in its entirety. Although in various implementations the size and shape of the filter212may vary, for example the length of the intermediate component110may be in an inclusive range of approximately 10 mm to 30 mm, the diameter of the intermediate component110may be in an inclusive range of approximately 3 mm to 8 mm, the length of the filter112may be in an inclusive range of approximately 10 mm to 20 mm, and the diameter of the filter112may be in an inclusive range of approximately 3 mm to 8 mm. In the depicted implementation, the filter112has a length of approximately 15 mm and a diameter of approximately 4.8 mm (and in some implementations, approximately 7 mm).

In various implementations, the mouthpiece214(e.g., the filter212) is configured to receive the generated aerosol therethrough in response to a draw applied to the mouthpiece214by a user. In some implementations, the mouthpiece214may be fixedly engaged to the substrate material (such as substrate material208). For example, an adhesive, a bond, a weld, and the like may be suitable for fixedly engaging the mouthpiece214to the substrate material208. In one example, the mouthpiece214is ultrasonically welded and sealed to the second end of the substrate material208.

As noted, in some implementations the mouthpiece214may comprise a filter212configured to receive the aerosol therethrough in response to the draw applied to the mouthpiece214. In various implementations, the filter212is provided, in some aspects, as a circular disc radially and/or longitudinally disposed proximate the second end of the second substrate material208. In this manner, upon draw on the mouthpiece214, the filter212receives the aerosol flowing through the intermediate component210of the smoking article200.

FIG. 7illustrates a cross-sectional schematic view of a heat source and a heat transfer component of a smoking article, according to another implementation of the present disclosure. In particular,FIG. 7illustrates a heat source504and a heat transfer component505that includes a heat transfer cap507. In various implementations, the heat source504of the depicted implementation may be similar to the heat sources described above, and thus reference is made to the various heat source implementations described herein. In the depicted implementation, the heat transfer component505comprises a solid cylinder that extends through the heat source504. As noted above, in other implementations, the heat transfer component may have other geometric configurations, including, for example, a tube, rod, sheet, or mesh. In the depicted implementations, the heat transfer component505is constructed of aluminum; however, as also noted above, in other implementations, the heat transfer component505may be constructed of other heat conducting materials, including, for example, stainless steel, brass, copper, silver, gold, bronze, graphite, and combinations thereof.

The implementation depicted inFIG. 7also includes a heat transfer cap507that is configured to cover an end of the heat source504proximate the substrate material. In the depicted implementation, the heat transfer cap507includes an end portion507A that covers substantially the entire end of the heat source504proximate the substrate material, and a rim portion507B that extends upward and peripherally around at least a portion of the length of the heat source504. In the depicted implementation, the rim portion507B of the heat transfer cap507extends approximately ⅓ to approximately ½ of the length of the heat source504. In the depicted implementation, the heat transfer cap507is constructed of the same material (e.g., aluminum) as the heat transfer component505. However, in other implementations, one or both the heat transfer component505or the heat transfer cap507may be constructed of another material, as described above. In addition, in various implementations, one or both the heat transfer component505or the heat transfer cap507may be constructed of one material (e.g., one conductive material) and coated with another material (e.g., another conductive material).

In the depicted implementation, the heat transfer component505extends through a portion of the heat source504and penetrates into a portion of the first substrate material (see above). In various implementations, the heat transfer component505may extend through any portion of the heat source504and may penetrate any portion of a substrate material. In some implementations, the heat transfer component may further extend into a portion of a second substrate material.

FIG. 8illustrates schematic views of various heat transfer components of a smoking article, according to some other example implementations of the present disclosure. In particular,FIG. 8illustrates a heat transfer component275, according to one implementation of the present disclosure, as well as heat transfer component305, according to another example implementation of the present disclosure, and heat transfer component405, according to still another example implementation of the present disclosure. In various implementations, each of the illustrated heat transfer components275,305,405is configured to facilitate the transfer of heat from a heat source to one or more downstream substrate materials.

Heat transfer component275of the present disclosure comprises a solid cylindrical tube or rod275A constructed of a copper material, that includes a coating275B comprising an aluminum material, although it should be noted that in other implementations, the cylindrical rod275A and the coating275B may be constructed of other materials, as noted above. Heat transfer component305differs in that it comprises a sheet305A constructed of a copper material, that includes a coating305B comprising an aluminum material, although it should be noted that in other implementations, the sheet305A and the coating305B may be constructed of other materials, as noted above. For example, in some implementations, the coating305B may comprise laminated sheets of aluminum on a copper body sheet. Although not shown in the figure, in various implementations the heat transfer component275and305may also include a heat transfer cap as described above. In still other implementations, heat transfer component275and/or the sheet305A may be constructed of an aluminum material and may not include a coating.

Heat transfer component405differs in that it comprises a mesh405A comprising an aluminum material, that includes an extension405B, located along the length thereof, which also comprises an aluminum material. It should be noted that in other implementations one or both of the mesh405A or the extension405B may be constructed of another material, as noted above. Although in the depicted implementation, the mesh405A has a substantially cylindrical shape (e.g., having a circular cross-section), in various other implementations, the mesh405A may have other geometric configurations (such as, for example, a substantially square, substantially rectangular, or substantially triangular cross-section). Likewise, although in the depicted implementation the extension405B has a disc shape, in various other implementations, the extension405B may have another shape (such as, for example, a substantially square or substantially triangular shape). In addition, although in various implementations the heat transfer component405may be configured such that the extension405B has any location along the heat source204and/or the substrate material206, in the depicted implementation the extension405B is configured to be positioned between the heat source204and the substrate material206.

FIG. 9illustrates a longitudinal cross-sectional schematic view of a smoking article700, according to another implementation of the present disclosure. In particular,FIG. 9depicts a smoking article700that includes a heat source704, a heat transfer component705, a first inhalable substance medium706, a second inhalable substance medium708, an intermediate component710, and a filter712. In the depicted implementation, the intermediate component710and the filter712together comprise a mouthpiece714. The smoking article700of the depicted implementation also includes a passageway717that is formed through the heat source704and through which the hollow structure of the heat transfer component705passes. As shown in the figure, in addition to the outer wrap702, the depicted implementation also includes a liner718that is configured to circumscribe the first substrate material706and at least a portion of the heat source704. As also shown in the figure, the outer wrap702(and, as necessary, the liner718, and the first substrate material706) may also include one or more openings720formed therethrough that allow the entry of air upon a draw on the mouthpiece714. One or more separate cooling openings721may also be formed in the outer wrap702in an area proximate the filter712.

In many respects, the implementation ofFIG. 9is similar to that ofFIG. 3, and thus reference is made to the descriptions above regarding the various possible components of the smoking article. One way in which the implementation ofFIG. 9differs from that ofFIG. 3is that the first substrate material706has an extruded hollow form that includes a passageway707formed therethrough. Although in the depicted implementation the diameter of the first substrate material passageway707is substantially the same as the passageway717formed through the heat source704, it should be noted that in various other implementations the diameter of the passageway707may differ. Thus in some implementations, the diameter of the first substrate material passageway707may be smaller than the diameter of the passageway717formed through the heat source704, and in other implementations, the diameter of the first substrate material passageway707may be larger than the diameter of the passageway717formed through the heat source704.

FIG. 10illustrates a longitudinal cross-sectional schematic view of a smoking article800, according to another implementation of the present disclosure. In particular,FIG. 10depicts a smoking article800that includes a heat source804, a heat transfer component805, a first inhalable substance medium806, an intermediate component810, and a filter812. In the depicted implementation, the intermediate component810and the filter812together comprise a mouthpiece814. The smoking article800of the depicted implementation also includes a passageway817that is formed through the heat source804and through which the hollow structure of the heat transfer component805passes. As shown in the figure, in addition to the outer wrap802, the depicted implementation also includes a liner818that is configured to circumscribe the first substrate material806and at least a portion of the heat source804. As also shown in the figure, the outer wrap802(and, as necessary, the liner818, and the first substrate material806) may also include one or more openings820formed therethrough that allow the entry of air upon a draw on the mouthpiece814. One or more separate cooling openings821may also be formed in the outer wrap702in an area proximate the filter812.

In many respects, the implementation ofFIG. 10is similar to that ofFIG. 3, and thus reference is made to the descriptions above regarding the various possible components of the smoking article. One way the implementation ofFIG. 10differs from that ofFIG. 3is that the first substrate material806has an extruded hollow form that includes a passageway807formed therethrough. Although in the depicted implementation the diameter of the first substrate material passageway807is substantially the same as the passageway817formed through the heat source804, it should be noted that in various other implementations the diameter of the passageway807may differ. Thus in some implementations, the diameter of the first substrate material passageway807may be smaller than the diameter of the passageway817formed through the heat source804, and in other implementations, the diameter of the first substrate material passageway807may be larger than the diameter of the passageway817formed through the heat source804.

Another way the implementation ofFIG. 10differs from that ofFIG. 3is that the implementation ofFIG. 10does not include a second substrate material. Thus, in some implementations the length of the first substrate material806and/or the length of the intermediate component810may be longer if it is desired to provide a smoking article of the same overall length. In the depicted implementation, the length of the intermediate component810has been increased to compensate for the lack of a second substrate material.

FIG. 11illustrates a longitudinal cross-sectional schematic view of a smoking article900, according to another implementation of the present disclosure. In particular,FIG. 11depicts a smoking article900that includes a heat source904, a heat transfer component905, a first inhalable substance medium906, a second inhalable substance medium908, an intermediate component910, and a filter912. In the depicted implementation, the intermediate component910and the filter912together comprise a mouthpiece914. The smoking article900of the depicted implementation also includes a passageway917that is formed through the heat source904and through which the hollow structure of the heat transfer component905passes. As shown in the figure, in addition to the outer wrap902, the depicted implementation also includes a liner918that is configured to circumscribe the first substrate material906and at least a portion of the heat source904. As also shown in the figure, the outer wrap902(and, as necessary, the liner918, and the first substrate material906) may also include one or more openings920formed therethrough that allow the entry of air upon a draw on the mouthpiece914. One or more separate cooling openings921may also be formed in the outer wrap in an area proximate the filter712.

In many respects, the implementation ofFIG. 11is similar to that ofFIG. 3, and thus reference is made to the descriptions above regarding the various possible components of the smoking article. One way in which the implementation ofFIG. 11differs from that ofFIG. 3is that the hollow structure of the heat transfer component905extends past the distal flange and into at least a portion of the first substrate material906. In other implementations, the hollow structure of the heat transfer component905may extend through the first substrate material906and into the second substrate material908.

Although a smoking article according to the disclosure may take on a variety of implementations, as discussed in detail herein, the use of the smoking article by a consumer will be similar in scope. The foregoing description of use of the smoking article is applicable to the various implementations described through minor modifications, which are apparent to the person of skill in the art in light of the further disclosure provided herein. The description of use, however, is not intended to limit the use of the inventive article but is provided to comply with all necessary requirements of disclosure herein.