JP2024023720A - Electronic smoking article comprising one or more microheaters - Google Patents

Abstract

To provide an electronic smoking article that provides improved aerosol delivery.SOLUTION: An article comprises one or more microheaters 50. The microheaters 50 are formed of a supporting layer 510, a protective layer 540, and a patterned electrically conductive layer 520 sandwiched between the supporting layer and the protective layer. In various embodiments, the microheaters 50 provide improved control of vaporization of an aerosol precursor composition and provide reduced power requirements to achieve consistent aerosolization.SELECTED DRAWING: Figure 1

Description

The present invention relates to aerosol delivery articles and their use for obtaining tobacco components or other substances in inhalable form. The article may be made of, derived from, or otherwise incorporate tobacco for human consumption.

Many smoking articles have been proposed over the years as improvements in burning tobacco or as replacements for smoking products based on tobacco combustion. Exemplary alternatives include devices that burn solid or liquid fuels or use chemical reactions to obtain such heat sources to transfer heat to the tobacco. A number of references propose a variety of smoking articles that produce flavored vapor, visible aerosol, or a mixture of flavored vapor and visible aerosol. These proposed types of smoking articles include tubular sections of pipes or longitudinally extending air passageways.

Improvements or alternative forms of smoking articles have typically been to obtain the sensation associated with smoking a cigarette, cigar, or pipe without delivering significant amounts of incomplete combustion and pyrolysis products. To this end, a number of smoking products, flavor generators and medicated inhalers have been proposed, which utilize electrical energy to evaporate or heat volatile substances, or which use cigarettes, cigars, etc. Or try to provide the feeling of smoking a pipe without burning the tobacco.

Other common examples of smoking articles are U.S. Pat. No. 3,258,015 to Ellis et al.; U.S. Pat. No. 3,356,094 to Ellis et al.; U.S. Pat. U.S. Pat. No. 4,347,855 to Bolt et al.; U.S. Pat. No. 4,340,072 to Bolt et al.; U.S. Patent No. 4,391,285 to Burnett et al.; U.S. Pat. ; U.S. Pat. No. 4,924,886 to Litzinger; and U.S. Pat. No. 5,060,676 to Hearn et al. Many of these types of smoking articles used a combustible fuel source that was combusted to provide the aerosol and/or heat the aerosol-forming material. See, for example, the background art cited in U.S. Patent No. 4,714,082 to Banerjee et al. and U.S. Patent No. 4,771,795 to White et al. thing. Also, for example, U.S. Pat. No. 4,756,318 to Clearman et al.; U.S. Pat. No. 4,714,082 to Banerjee et al.; U.S. Pat. , 793,365; U.S. Patent No. 4,917,128 to Clearman et al.; U.S. Patent No. 4,961,438 to Korte; U.S. Patent No. 4,966,171 to Serrano et al.; No. 4,969,476; U.S. Patent No. 4,991,606 to Serrano et al.; U.S. Patent No. 5,020,548 to Farrier et al.; U.S. Patent No. 5,033,483 to Clearman et al.; Patent No. 5,040,551; U.S. Patent No. 5,050,621 to Creighton et al.; U.S. Patent No. 5,065,776 to Lawson; U.S. Patent No. 5,076,296 to Nystrom et al.; U.S. Patent No. 5,076,297; U.S. Patent No. 5,099,861 to Clearman et al.; U.S. Patent No. 5,105,835 to Drewett et al.; U.S. Patent No. 5,105,837 to Barnes et al.; Hauser US Pat. No. 5,115,820 to Best et al.; US Pat. No. 5,148,821 to Best et al.; US Pat. No. 5,159,940 to Hayward et al.; US Pat. No. 5,178,167 to Riggs et al. ; U.S. Patent No. 5,183,062 to Clearman et al.; U.S. Patent No. 5,211,684 to Shannon et al.; U.S. Patent No. 5,240,014 to Deevi et al.; US Pat. No. 5,345,955 to Clearman et al.; US Pat. No. 5,551,451 to Riggs et al.; US Pat. No. 5,595,577 to Bensalem et al.; US Pat. No. 819,751; US Pat. No. 6,089,857 to Matsuura et al.; US Pat. No. 6,095,152 to Beven; US Pat. No. 6,578,584 to Beven; and US Pat. See also the types of smoking articles described in No. 730,832, which are incorporated herein by reference in their entirety. In addition, specialty cigarettes using carbonaceous fuel elements are sold under the trade names "Premier" and "Eclipse" by R. J. It is commercially available from Reynolds Tobacco Company. For example, Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burning Tobacco, R. J. See cigarettes of the type described in Reynolds Tobacco Company Monograph (1988) and Inhalation Toxicology, 12:5, pages 1-58 (2000). Also, US Patent Application Publication No. 2005/0274390 to Banerjee et al., US Patent Application Publication No. 2007/0215167 to Crooks et al., US Patent Application Publication No. 2010/0065075 to Banerjee et al., and US Patent Application Publication No. 2010/0065075 to Stone et al. See also 2012/0042885, the disclosure of which is incorporated herein by reference in its entirety.

Certain cigarette-shaped tobacco products that have been proposed are said to use tobacco in a form that is intended to be less completely combusted. For example, U.S. Pat. No. 4,836,225 to Sudoh; U.S. Pat. No. 4,972,855 to Kuriyama et al.; and U.S. Pat. (incorporated). Still other types of smoking articles, such as those that produce a flavored vapor by subjecting tobacco or processed tobacco to heat generated from a chemical or electrical heat source, are discussed in Chard et al. U.S. Patent No. 4,848,374; U.S. Patent No. 4,947,874 and 4,947,875 to Brooks et al.; U.S. Patent No. 5,060,671 to Counts et al.; U.S. Patent No. 5,060,671 to Deevi et al. No. 5,146,934; U.S. Patent No. 5,224,498 to Deevi; U.S. Patent No. 5,285,798 to Banerjee et al.; U.S. Patent No. 5,357,984 to Farrier et al.; Patent No. 5,593,792; U.S. Patent No. 5,369,723 to Counts; U.S. Patent No. 5,692,525 to Counts et al.; U.S. Patent No. 5,865,185 to Collins et al.; U.S. Patent No. 5,878,752; U.S. Patent No. 5,880,439 to Deevi et al.; U.S. Patent No. 5,915,387 to Baggett et al.; U.S. Patent No. 5,934,289 to Watkins et al.; U.S. Patent No. 6,033,623 to Adams et al.; U.S. Patent No. 6,053,176 to Adams et al.; U.S. Patent No. 6,164,287 to White; U.S. Patent No. 6,289,898 to Fournier et al. US Patent Application No. 6,615,840 to Fournier et al; US Patent Application Publication No. 2003/0131859 to Li et al; US Patent Application Publication No. 2005/0016549 to Banerjee et al; No. 0185687, each of which is incorporated herein by reference in its entirety.

Certain attempts have been made to deliver vapors, sprays or aerosols, such as those that carry or incorporate flavors and/or nicotine. For example, US Pat. No. 4,190,046 to Virag; US Pat. No. 4,284,089 to Ray; US Pat. No. 4,635,651 to Jacobs; US Pat. 5,388,574 to Ingebrethsen et al.; 5,799,663 to Gross et al.; 6,532,965 to Abhulimen et al.; and Adiga et al. No. 6,598,607; European Patent No. 1,618,803 to Hon; devices of the type shown in US Pat. No. 7,117,867 to Cox et al; and the website www. e-cig. com, all of which are incorporated herein by reference in their entirety.

Still more representative cigarettes or smoking articles that have been described and in some cases commercially available include U.S. Pat. No. 4,922,901 to Brooks et al.; U.S. Pat. No. 5,249,586 to Morgan et al. US Pat. No. 5,388,594 to Counts et al.; US Pat. No. 5,666,977 to Higgins et al.; US Pat. No. 6,196,218 to Voges; US Pat. No. 6,810,883 to Felter et al. US Patent No. 6,854,461 to Nichols; US Patent No. 7,832,410 to Hon; US Patent No. 7,513,253 to Kobayashi; US Patent No. 7,726,320 to Robinson et al. ; U.S. Patent No. 7,896,006 to Hamano; U.S. Patent No. 6,772,756 to Shayan; U.S. Patent Application Publication No. 2009/0095311 to Hon; 2009/0126745 and 2009/0188490; U.S. Patent Application Publication No. 2009/0272379 to Thorens et al.; U.S. Patent Application Publication No. 2009/0260641 and 2009/0260642 to Monsees et al.; These include those described in US Patent Application Publication Nos. 2008/0149118 and 2010/0024834; US Patent Application Publication No. 2010/0307518 to Wang; and WO 2010/091593 to Hon. See also US Pat. Still further examples include: ACCORD(R); HEATBAR(R); HYBRID CIGARETTE(R); VEGAS(R); E-GAR(R); C-GAR(R); E-MYSTICK(R); IOLITE(R) Vaporizer, GREEN SMOKE(R), BLU(R) Cigs, WHITE CLOUD(R) Cirrus, V2CIGS(R), SOUTH BEACH SMOKE(R), SMOKETIP(R), SMOKE S TIK (registration) Trademark), NJOY (registered trademark), LUCI (registered trademark), Royal Blues, SMART SMOKER (registered trademark), SMOKE ASSIST (registered trademark), Knight Sticks, GAMUCCI (registered trademark), InnoVapor, SMOKING EVERYWHERE (registered trademark) trademark), Crown7, CHOICE(TM) NO. 7 (trademark), VAPORKING (registered trademark), EPUFFER (registered trademark), LOGIC (trademark) ecig, VAPOR4LIFE (registered trademark), NICOTEK (registered trademark), METRO (registered trademark), VUSE (registered trademark), and PREMIUM ( Examples include e-cigarette products marketed under the trademark (Trademark).

U.S. Patent No. 3,258,015 U.S. Patent No. 3,356,094 U.S. Patent No. 3,516,417 U.S. Patent No. 4,347,855 U.S. Patent No. 4,340,072 U.S. Patent No. 4,391,285 U.S. Patent No. 4,917,121 U.S. Patent No. 4,924,886 US Patent No. 5,060,676 U.S. Patent No. 4,714,082 U.S. Patent No. 4,771,795 U.S. Patent No. 4,756,318 U.S. Patent No. 4,793,365 U.S. Patent No. 4,917,128 U.S. Patent No. 4,961,438 U.S. Patent No. 4,966,171 U.S. Patent No. 4,969,476 U.S. Patent No. 4,991,606 US Patent No. 5,020,548 US Patent No. 5,033,483 US Patent No. 5,040,551 US Patent No. 5,050,621 US Patent No. 5,065,776 US Patent No. 5,076,296 US Patent No. 5,076,297 US Patent No. 5,099,861 US Patent No. 5,105,835 US Patent No. 5,105,837 US Patent No. 5,115,820 US Patent No. 5,148,821 US Patent No. 5,159,940 US Patent No. 5,178,167 US Patent No. 5,183,062 US Patent No. 5,211,684 US Patent No. 5,240,014 US Patent No. 5,240,016 US Patent No. 5,345,955 US Patent No. 5,551,451 US Patent No. 5,595,577 US Patent No. 5,819,751 US Patent No. 6,089,857 US Patent No. 6,095,152 US Patent No. 6,578,584 US Patent No. 6,730,832 US Patent Application Publication No. 2005/0274390 US Patent Application Publication No. 2007/0215167 US Patent Application Publication No. 2010/0065075 US Patent Application Publication No. 2012/0042885 U.S. Patent No. 4,836,225 U.S. Patent No. 4,972,855 US Patent No. 5,293,883 U.S. Patent No. 4,848,374 U.S. Patent No. 4,947,874 U.S. Patent No. 4,947,875 US Patent No. 5,060,671 US Patent No. 5,146,934 US Patent No. 5,224,498 US Patent No. 5,285,798 US Patent No. 5,357,984 US Patent No. 5,593,792 US Patent No. 5,369,723 US Patent No. 5,692,525 US Patent No. 5,865,185 US Patent No. 5,878,752 US Patent No. 5,880,439 US Patent No. 5,915,387 US Patent No. 5,934,289 US Patent No. 6,033,623 US Patent No. 6,053,176 US Patent No. 6,164,287 US Patent No. 6,289,898 US Patent No. 6,615,840 US Patent Application Publication No. 2003/0131859 US Patent Application Publication No. 2005/0016549 US Patent Application Publication No. 2006/0185687 U.S. Patent No. 4,190,046 U.S. Patent No. 4,284,089 U.S. Patent No. 4,635,651 U.S. Patent No. 4,735,217 U.S. Patent No. 4,800,903 US Patent No. 5,388,574 US Patent No. 5,799,663 US Patent No. 6,532,965 US Patent No. 6,598,607 European Patent No. 1,618,803 US Patent No. 7,117,867 U.S. Patent No. 4,922,901 US Patent No. 5,249,586 US Patent No. 5,388,594 US Patent No. 5,666,977 US Patent No. 6,196,218 US Patent No. 6,810,883 US Patent No. 6,854,461 US Patent No. 7,832,410 US Patent No. 7,513,253 U.S. Patent No. 7,726,320 US Patent No. 7,896,006 US Patent No. 6,772,756 US Patent Application Publication No. 2009/0095311 US Patent Application Publication No. 2006/0196518 US Patent Application Publication No. 2009/0126745 US Patent Application Publication No. 2009/0188490 US Patent Application Publication No. 2009/0272379 US Patent Application Publication No. 2009/0260641 US Patent Application Publication No. 2009/0260642 US Patent Application Publication No. 2008/0149118 US Patent Application Publication No. 2010/0024834 US Patent Application Publication No. 2010/0307518 International Publication No. 2010/091593 US Patent No. D657,047 US Patent Application Publication No. 2011/0277757 US Patent Application Publication No. 2011/0277760 US Patent Application Publication No. 2011/0277764

Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988) Inhalation Toxicology, 12:5, p. 1-58 (2000)

Smoking articles that use tobacco substitutes and that use heat sources other than burning tobacco cut filters (because they produce tobacco-flavored vapors or visible tobacco-flavored aerosols) have not had great commercial success. Articles that produce the flavor and sensation of smoking by electrically heating tobacco have specifically suffered from inconsistent release of flavor or other inhalable substances. Electrically heated smoking devices have also often been limited to the requirements of external heating devices, which is inconvenient and detracts from the smoking experience. Thus, you get the feeling of smoking a cigarette, cigar or pipe without significantly burning tobacco, without the need for a combustion heat source, and without the need to deliver significant amounts of incomplete combustion and pyrolysis products. It may be desirable to have a smoking article that can be used.

The present invention provides smoking articles and their use for controllably delivering aerosol precursor components. As used herein, a composition for providing a desired result to the consumer of this article, such as achieving an experience substantially similar to smoking a conventional cigarette, or achieving the delivery of flavor, etc. Articles incorporating one or more microheaters for use in vaporizing or aerosolizing substances are disclosed.

In various embodiments, smoking articles according to the present disclosure may include a power source and a microheater electrically connected to the power source. This microheater can be characterized as a microelectromechanical systems (MEMS) based heater. Alternatively, the microheater may be characterized as being a thin film heater.

The properties of microheaters useful in accordance with the present disclosure may vary. In various embodiments, the microheater may include a patterned conductive material. For example, the conductive material may be selected from the group consisting of elemental metals, metal alloys, silicon, ceramics, carbon, carbides, nitrides, and combinations thereof. The microheater may include a support layer on which a conductive material is patterned. For example, the conductive material may be a printed layer laminated to the support layer. Alternatively, the conductive material may be an etched layer laminated to the support layer. Preferably, the support layer is temperature stable over some defined temperature range, such as a temperature range of about 125°C to about 750°C. In certain embodiments, the support layer may include a silicon base, such as silicon nitride. The microheater may include a protective layer laminated to the patterned conductive material. Preferably, the protective layer is temperature stable over some defined temperature range, such as a temperature range of about 125°C to about 750°C. In certain embodiments, this protective layer may include a silicon-based material, such as silicon dioxide. As understood from the foregoing, microheaters useful in the articles of the present disclosure may include more than one layer. For example, the microheater may be characterized as comprising an electrically conductive material sandwiched between two layers or two membranes. The microheaters disclosed herein may also have defined dimensions. For example, the microheater may have a length of about 3 mm or less and a width of about 3 mm or less. More specifically, the microheater may have a length of about 0.5 mm to about 3 mm and a width of about 0.5 mm to about 3 mm.

Microheaters for use in the articles disclosed herein can be utilized independently of additional components. In other embodiments, the microheater may be attached to the substrate. Such a substrate may be a permanent fixture of the article, or the substrate may be removable from the smoking article. Preferably, this substrate may be formed from an electrically insulating material.

In certain embodiments, smoking articles according to the present disclosure may include multiple microheaters. If desired, the plurality of microheaters may be arranged in series within the smoking article. Thus, this series of microheaters can be arranged in a predetermined order (e.g. in succession) or in a prescribed pattern (e.g. two or more microheaters heated separately or two or more microheaters heated in succession). may be adapted to be heated with one or more microheaters).

The smoking articles disclosed herein may further include an aerosol precursor composition. In certain embodiments, the microheater may be operably disposed within the smoking article such that it is in substantial contact with the aerosol precursor composition. Additionally, the aerosol precursor composition may exist in various forms, such as in liquid or gel form at ambient conditions. If desired, the aerosol precursor composition may alternatively be in solid form at ambient conditions. In certain embodiments, the aerosol precursor composition may be in the form of a gel that is coated onto the microheater.

In other embodiments, the aerosol precursor composition may be provided in a reservoir such that the aerosol precursor composition is spaced from the microheater. Accordingly, the article may include a controller adapted to deliver a predetermined amount of aerosol precursor composition to the microheater. In certain embodiments, the microheater may be thermally coupled to a chamber formed from a wall, the chamber configured to receive a predetermined amount of aerosol precursor composition through an opening in the chamber. It is adapted to. The chamber may be provided with an opening adapted for the exit of steam from the chamber and/or may be provided with an opening suitable for filtration of air. In certain embodiments, the chamber may have a volume of about 0.2 ml to about 1 ml. Such embodiments may be adapted to individually heat separate compositions or components thereof. For example, the aerosol precursor composition may include a plurality of individual components, and the smoking article may separately include a plurality of reservoirs containing the individual components of the aerosol precursor composition; The article may include a plurality of chambers adapted to receive predetermined amounts of individual components of the aerosol precursor composition from the reservoir.

In still further embodiments, the aerosol precursor composition may be coated onto, adsorbed to, or absorbed into a carrier material. Furthermore, the carrier material may be placed within the article so as to be in substantial contact with the microheater. Optionally, the article may include a plurality of microheaters in substantial contact with the carrier material.

The aerosol precursor composition may include various components. For example, the composition may include one or more of a polyhydric alcohol, a drug, a tobacco-derived substance, and a flavor.

The power source may be selected from the group consisting of batteries, capacitors, and combinations thereof. Additionally, the article may include a control component that operates electrical current from the power source to the microheater. For example, the control component may include a puff-actuated sensor or a capacitive sensor.

In further embodiments, the smoking article may be characterized with respect to the atomizer used therein. For example, the smoking article may include a microheater that is integral to the atomizer. More specifically, the nebulizer may comprise a chamber defined by a wall, a cover and a protective layer laminated to the microheater. Additionally, one or both of the wall and cover may include a plurality of apertures sized to permit passage of vapor but not liquid.

Accordingly, the present disclosure may also encompass atomizers suitable for use in electric smoking articles. For example, the nebulizer may include a chamber formed by a chamber wall, a cover and a microheater. The chamber wall and cover may be integral or attached to a support or protective layer of the microheater as discussed herein. One or both of the chamber wall and cover may include a plurality of apertures sized to permit passage of vapor but not liquid.

In further embodiments, the present disclosure may relate to a method of forming an aerosol in a smoking article. For example, the method includes initiating electrical current from a power source within the smoking article to a microheater within the smoking article, thereby heating the microheater and an aerosol precursor composition in contact with the microheater. May be included.

In certain embodiments, a smoking article utilized in this method may include a plurality of microheaters, and two or more of the microheaters may be heated simultaneously. Furthermore, the aerosol precursor composition may include two or more individual components, and the individual components of the aerosol precursor composition may be heated separately by a microheater. Furthermore, the microheater may receive current from a power source under different conditions such that the microheater is heated to different temperatures or heated for different times. In some embodiments, two or more microheaters may be heated in succession.

If desired, the aerosol precursor composition may be coated onto, adsorbed to, or absorbed into a carrier material. Furthermore, prior to the step of activating the current, the method may further include inserting a carrier material into the smoking article. In further embodiments, the microheater may be attached to the substrate. Similarly, prior to activating the current, the method may further include inserting the substrate into the smoking article. Advantageously, this aerosol precursor composition may be coated onto a microheater attached to a substrate. In a further embodiment, the method initiates flow of the aerosol precursor composition from a reservoir to a chamber that is thermally coupled to a microheater, thereby causing the aerosol precursor composition in the chamber to It may further include heating.

The present invention includes, but is not limited to, the following embodiments.

Embodiment 1: A smoking article comprising a power source and a microheater electrically connected to the power source.

Embodiment 2: A smoking article according to any of the preceding or subsequent embodiments, wherein the microheater is a microelectromechanical systems (MEMS)-based heater.

Embodiment 3: A smoking article according to any of the preceding or subsequent embodiments, wherein the microheater is a thin film heater.

Embodiment 4: The smoking article of any of the preceding or subsequent embodiments, wherein the microheater comprises a patterned conductive material.

Embodiment 5: The electrically conductive material is selected from the group consisting of elemental metals, metal alloys, silicon, ceramics, carbon, carbides, nitrides, and combinations thereof. smoking articles.

Embodiment 6: The smoking article of any of the preceding or subsequent embodiments, wherein the microheater includes a support layer, and a conductive material is patterned on the support layer.

Embodiment 7: The conductive material is a printed layer laminated to a support layer, or the conductive material is an etched layer laminated to a support layer. A smoking article according to any of the embodiments.

Embodiment 8: The smoking article of any of the preceding or subsequent embodiments, wherein the microheater comprises a protective layer laminated to a patterned conductive material.

Embodiment 9: The smoking article of any of the preceding or subsequent embodiments, wherein the support layer or protective layer is temperature stable in a temperature range of about 125°C to about 750°C.

Embodiment 10: A smoking article according to any of the preceding or subsequent embodiments, wherein the support layer or protective layer comprises a silicon-based material.

Embodiment 11: The smoking article of any preceding or subsequent embodiment, wherein the microheater comprises two or more layers.

Embodiment 12: The smoking article of any preceding or subsequent embodiment, wherein the microheater comprises an electrically conductive material sandwiched between two membranes.

Embodiment 13: The smoking article of any preceding or subsequent embodiment, wherein the microheater has a length of about 3 mm or less and a width of about 3 mm or less.

Embodiment 14: The smoking article of any preceding or subsequent embodiment, wherein the microheater has a length of about 0.5 mm to about 3 mm and a width of about 0.5 mm to about 3 mm.

Embodiment 15: A smoking article according to any of the preceding or subsequent embodiments, wherein the microheater is attached to a substrate.

Embodiment 16: A smoking article as in any preceding or subsequent embodiment, wherein the substrate is formed from an electrically insulating material.

Embodiment 17: A smoking article according to any of the preceding or subsequent embodiments, comprising a plurality of microheaters.

Embodiment 18: A smoking article according to any preceding or subsequent embodiment, further comprising an aerosol precursor composition.

Embodiment 19: A smoking article according to any of the preceding or subsequent embodiments, wherein the aerosol precursor composition is in liquid or gel form at ambient conditions.

Embodiment 20: The smoking article of any of the preceding or subsequent embodiments, wherein the aerosol precursor composition is in a reservoir such that the aerosol precursor composition is spaced from the microheater.

Embodiment 21: A smoking article according to any of the preceding or subsequent embodiments, wherein the article comprises a controller adapted to deliver a predetermined amount of the aerosol precursor composition to the microheater.

Embodiment 22: The microheater is thermally coupled to a chamber, the chamber being adapted to receive a predetermined amount of the aerosol precursor composition through an opening therein. A smoking article according to any of the forms.

Embodiment 23: A smoking article according to any of the preceding or subsequent embodiments, wherein the chamber comprises an opening adapted for the exit of vapor from the chamber.

Embodiment 24: A smoking article according to any of the preceding or subsequent embodiments, wherein the chamber has a volume of about 0.2 ml to about 1 ml.

Embodiment 25: The aerosol precursor composition may be coated onto, adsorbed to, or absorbed into a carrier material, wherein the carrier material is substantially in contact with the microheater. A smoking article according to any of the preceding or subsequent embodiments, wherein the smoking article is disposed within an article that contacts a smoking article.

Embodiment 26: A smoking article according to any of the preceding or subsequent embodiments, wherein the microheater is integral with an atomizer.

Embodiment 27: A smoking article according to any of the preceding or subsequent embodiments, wherein the atomizer comprises a chamber defined by a wall, a cover, and a protective layer laminated to a microheater.

Embodiment 28: A smoking article according to any of the preceding or subsequent embodiments, wherein one or both of the wall and cover comprises a plurality of openings sized to permit passage of vapor but not passage of liquid. .

Embodiment 29: A method of forming an aerosol in a smoking article, the method comprising: causing a current from a power source within the smoking article to flow through a microheater within the smoking article, thereby contacting the microheater and the microheater. A method comprising heating an aerosol precursor composition comprising:

Embodiment 30: A method as in any preceding or subsequent embodiment, wherein the smoking article comprises a plurality of microheaters.

Embodiment 31: The method is characterized in that the aerosol precursor composition is coated on, adsorbed to, or absorbed into a carrier material, and before the step of activating the electrical current. , the method of any preceding or subsequent embodiment, further comprising inserting a carrier material within the smoking article.

Embodiment 32: Initiating flow of the aerosol precursor composition from a reservoir to a chamber that is thermally coupled to the microheater, thereby heating the aerosol precursor composition in the chamber. A method according to any preceding or subsequent embodiment, further comprising:

Embodiment 33: A nebulizer suitable for use in an electronic smoking article, comprising a chamber formed from a chamber wall, a cover, and a microheater.

Embodiment 34: A nebulizer as in any preceding or subsequent embodiment, wherein one or both of the chamber wall and cover comprises a plurality of openings.

Embodiment 35: The atomizer of any of the preceding or subsequent embodiments, wherein one or more of the plurality of openings is sized to pass vapor but not liquid.

These and other features, aspects, and advantages of the present disclosure will become apparent from the following detailed description and the accompanying drawings (described briefly below). This disclosure describes any combination of two, three, four, or more of the embodiments described above, and any two, three, four, or more features or elements shown in this disclosure, including any such combinations. Features and elements are included whether or not explicitly combined in the description of a particular embodiment herein. This disclosure is to be read in its entirety, so that any separable features or elements of the disclosed subject matter, in any of its various aspects and embodiments, are to be read in their entirety, unless the context clearly indicates otherwise. , should be considered combinable.

Having thus described the invention in the foregoing general terms, reference is now made to the accompanying drawings. The drawings are not necessarily drawn to scale.

1 is a perspective view of an exemplary embodiment of a microheater according to the present disclosure; FIG. 1 is a perspective view of an exemplary embodiment of a smoking article according to the present disclosure, with a portion of the outer shell of the article cut away to reveal its internal components; FIG. 1 is a perspective view of an exemplary embodiment of a smoking article according to the present disclosure, the article comprising a control body and a cartridge removable therefrom; FIG. 1 is a perspective view of a substrate with a plurality of micro-heaters thereon, according to an exemplary embodiment of the present disclosure; FIG. 5 is a longitudinal cross-sectional view of the substrate shown in FIG. 4 along line AA, showing a microheater housed within a well in the substrate and covered with an aerosol precursor composition; FIG. 1 is a perspective view of a substrate according to an exemplary embodiment of the present disclosure, where the substrate includes two layers with a plurality of micro-heaters therebetween; FIG. 1 is a perspective view of an exemplary embodiment of a smoking article according to the present disclosure, wherein the article has a cavity therein receiving a substrate containing an aerosol precursor composition and lined with a plurality of microheaters; FIG. comprises a single body with a swing door providing access to the 1 is a perspective view of a sprayer according to an exemplary embodiment of the present disclosure; FIG. FIG. 3 is a perspective view of a further atomizer according to an exemplary embodiment of the present disclosure.

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

The present invention provides an article that uses electrical energy to heat a material (preferably without burning the material to any extent) to form an inhalable substance; It is small enough to be considered a "hand-held" device. In certain embodiments, the article may be specifically characterized as a smoking article. As used herein, the term refers to the taste and/or sensation (e.g., the sensation in the hands or sensation in the mouth) of smoking a cigarette, cigar, or pipe without substantial combustion of any of the components of the article. shall mean the goods obtained. The term smoking article does not necessarily indicate that, during operation, the article produces smoke in the sense of by-products of combustion or pyrolysis. Rather, smoking refers to the physical activity of an individual in using the article, such as holding the article, inhaling against one end of the article, and inhaling from the article. In further embodiments, articles of the invention may be characterized as being vapor generating articles, aerosolizing articles, or drug delivery articles. Accordingly, the article may be arranged to provide one or more substances in an inhalable form. In other embodiments, the inhalable substance may be in substantially vapor form (ie, a substance that is in the gas phase at a temperature below its critical point). In other embodiments, the inhalable substance may be in the form of an aerosol (ie, a suspension of solid particles or droplets in a gas). The physical form of the inhalable substance need not be limited to the nature of the article of the invention, but depends on the nature of the medium and the inhalable substance itself, whether it is present in a vapor state or in an aerosol state. It shall depend upon the In some embodiments, the terms may be interchangeable. It is therefore understood that, for simplicity, the terms used to describe the present invention are interchangeable, unless stated otherwise.

In one aspect, the invention provides a smoking article. The smoking article may generally include multiple components provided within the elongated body, whether a single, single shell or two or more separable pieces. It may be a form. For example, a smoking article according to one embodiment may include a shell (i.e., an elongated body) that may have a substantially tubular shape, such as mimicking the shape of a traditional cigarette or cigar. . Within this shell all components of the smoking article may be present (one or more of which may be replaceable). In other embodiments, the smoking article may include two shells that are connected and separable. For example, the control body may include a shell that includes one or more reusable components and has an end that removably couples to the cartridge. The cartridge includes one or more disposable components and may include a shell having an end that removably couples to the control body. More specific arrangements of components within a single shell or within a separable control body and cartridge will be apparent in view of the further disclosure provided herein.

A smoking article according to the invention comprises a power source (i.e. a power source), one or more control components (e.g. for controlling/actuating/regulating the flow of power from the power source to one or more further components of the article). ), heater components, and aerosol precursor components. The smoking article may further include a defined air flow path through the article so that an aerosol produced by the article can be drawn therefrom by a user inhaling the article. The arrangement of components within this article may vary. In certain embodiments, the aerosol precursor component may be placed near the end of the article near the user's mouth, thereby maximizing aerosol delivery to the user. However, other configurations are not excluded. Generally, the heater component may be placed close enough to the aerosol precursor component such that heat from the heater component is directed to the aerosol precursor (as well as to one or more fragrances, drugs, or users). (the same that may be provided for delivery) may be volatilized to form an aerosol for delivery to the user. When the heating member heats the aerosol precursor component, an aerosol (alone or further comprising an inhalable substance) is formed, emitted or produced in a physical form suitable for inhalation by a consumer. It should be noted that the aforementioned terms are meant to be interchangeable. Thus, the terms "release," "production," and "formation" may be interchangeable, and the terms "release," "production," and "formation" may be interchangeable. The terms "emit," "produce," and "form" may be used interchangeably, and the terms "emitted," "produced," and "formed" may be used interchangeably. It's good to be there. Specifically, the inhalable substance is released as a vapor or an aerosol or a mixture thereof.

A smoking article according to the invention includes a heating member for heating an aerosol precursor component to produce an aerosol for inhalation by a user. Smoking articles as described herein may be particularly characterized by comprising a microheater as heating element. In particular, the microheater may be electrically connected to a power source, as further described herein. The smoking article may include only a single microheater. However, in other embodiments, the smoking article may include multiple microheaters. It is therefore understood that the present disclosure may describe smoking articles in terms of "an" microheater or "the" microheater. , this disclosure is meant to encompass embodiments in which the smoking article comprises multiple microheaters.

In some embodiments, the microheater used in the smoking articles described herein may be characterized as a microelectromechanical systems (MEMS)-based heater. MEMS-based heaters are currently used in ultra-small microsensors such as wind sensors, humidity sensors, and gas sensors. Such MEMS-based microheaters can radiate heat by applying current to a resistor and can offer advantages such as low power input requirements and extremely short response times. MEMS-based microheaters, as described herein, are highly advantageous in smoking articles. This is because the microheater may provide low voltage and/or low power device functionality.

The microheaters used in the smoking articles described herein may also be characterized as thin film heaters or hot film heaters. This may be characteristic of the physical properties of the microheater, which may be equipped with an electrically conductive material, which may in particular be provided in the form of a membrane (ie an electrically conductive layer). In certain embodiments, the conductive material may be patterned. In other words, this conductive material may be present in the microheater in a particular pattern and thus refers to the physical properties of the finished microheater and is not limited to the method of making that microheater. The thickness of the conductive layer may vary, for example, about 5 μm or less, about 4 μm or less, about 3 μm or less, about 2 μm or less, about 1 μm or less, about 0.75 μm or less, about 0.5 μm or less, about It may be 0.25 μm or less, about 0.1 μm or less, or about 0.075 μm or less. In other embodiments, the conductive layer is about 0.01 μm to about 5 μm, about 0.05 μm to about 3 μm, about 0.1 μm to about 2.5 μm, about 0.2 μm to about 2 μm, or about 0. It may have a thickness of 5 μm to about 1 μm.

The electrically conductive material used in the microheater may include almost any material that is electrically conductive in the size range discussed above and suitable for thin film formation. For example, the conductive material may be selected from the group consisting of elemental metals, metal alloys, silicon (including single crystal silicon and polycrystalline silicon), ceramics, carbon, carbides, nitrides, and combinations thereof. In more particular embodiments, the conductive material is formed from platinum, gold, silver, copper, aluminum, tungsten, zinc, nickel, titanium, nichrome, silicon carbide, polycrystalline silicon, single crystal silicon, titanium nitride, etc. obtain. In certain embodiments, elemental metals, such as platinum, may be particularly beneficial due to their excellent oxidation resistance and long-term stability. Thin film microheaters according to the present disclosure may exhibit high levels of durability and stability, which may be preferable to more fragile and less stable hot wires.

In addition to the conductive layer, the microheater according to the present disclosure may include a support layer. In particular, a conductive material may be patterned onto such a support layer. This support layer is preferably formed from a material that is temperature stable under the operating temperature of the heater. For example, the support layer may be temperature stable at temperatures of about 150°C or higher, about 200°C or higher, about 300°C or higher, about 400°C or higher, or about 500°C or higher. In other embodiments, the support layer may be temperature stable in a temperature range of about 125°C to about 750°C, about 150°C to about 650°C, or about 175°C to about 500°C. In some embodiments, this support layer may be formed from a ceramic material, particularly a silicon-based material. One particular example of a support layer material is a silicon nitride material. However, other materials may also be used, for example glass or quartz. Certain thermoplastic materials may also be used, such as cyclic olefin copolymers (COC). This support layer may be formed from an insulating material or may include an insulating layer.

The microheater according to the present disclosure may further include a protective layer laminated on the conductive layer. This protective layer is preferably formed from a material such that it is temperature stable and thermally emissive and/or thermally conductive under the operating temperature for the microheater. For example, the protective layer may be temperature stable at temperatures of about 150°C or higher, about 200°C or higher, about 300°C or higher, about 400°C or higher, or about 500°C or higher. In other embodiments, the protective layer may be temperature stable in a temperature range of about 125°C to about 750°C, about 150°C to about 650°C, or about 175°C to about 500°C. In some embodiments, this protective layer may be contacted directly with the aerosol precursor composition or components thereof. Therefore, it is preferred for the protective layer to be substantially chemically non-reactive with the various compounds that may be included in the aerosol precursor material. Substantially chemically non-reactive means that any chemical reaction between the protective layer and the components of the aerosol precursor material is sufficiently limited such that the protective layer is not breached. , thereby meaning allowing the aerosol precursor composition to indirectly contact the electrically conductive layer of the microheater. Alternatively, the phrase states that any chemical reaction between the protective layer and the components of the aerosol precursor material is sufficiently limited so that the compounds present in the protective layer are released (or de novo (formed) and thereby not combined with the formed aerosol for inhalation by the consumer. In some embodiments, this support layer may be formed from a ceramic material, particularly a silicon-based material. One particular example of a support layer material is a silicon dioxide material. However, other materials may also be used, for example glass or quartz.

This microheater may be particularly characterized as being a multilayer article. Specifically, this microheater may include two or more layers. In other embodiments, the microheater may be characterized as comprising a conductive material sandwiched between two layers or two membranes. The thickness of further layers such as the support layer and the protective layer may vary depending on the application. In some embodiments, the additional layer may be of similar size to the conductive layer. In other embodiments, the additional layers may be thicker than the conductive layer, e.g., each independently less than or equal to about 0.5 mm, less than or equal to about 0.75 mm, less than or equal to about 1 mm, less than or equal to about 1.5 mm. , about 2 mm or less, or about 5 mm or less.

This microheater, in its functioning form, can be similarly characterized with respect to its further dimensions. Specifically, the microheaters can each independently have a length and width of about 5 mm or less, about 4 mm or less, about 3 mm or less, or about 2 mm or less. In other embodiments, the length and width of the microheater are each independently about 0.25 mm to about 5 mm, about 0.5 mm to about 3 mm, about 0.6 mm to about 2.5 mm, about 0.7 mm. to about 2 mm, or from about 0.75 mm to about 1.5 mm.

An exemplary embodiment of a microheater that may be used in accordance with the present disclosure is shown in FIG. As can be seen, the microheater 50 is formed from a support layer 510, a protective layer 540, and a patterned conductive layer 520 sandwiched between the support layer and the protective layer. Each layer may be formed from materials as described herein and have dimensions as described herein. The microheater also extends from the conductive layer and electrically connects the microheater (particularly the conductive material) with further electrical components of the articles described herein, including various controller components and a power source. A contact terminal 530 is also provided. Preferably, the microheater is placed within an article as described herein so that its terminals do not come into contact with the aerosol precursor composition. Furthermore, the microheater may further comprise a component designed to space the terminals from the part of the barrier layer that is contacted with the aerosol precursor composition for aerosol formation. As illustrated, the protective layer is partially transparent, but microheaters useful as described herein do not necessarily have to be transparent, and such features may depend on the materials utilized. You can change it accordingly. Similarly, the support layer and the protective layer may have the same or different dimensions, and the patterning of the conductive layer may vary.

Microheaters useful in smoking articles such as those described herein can be prepared in a variety of suitable processes. For example, low pressure chemical vapor deposition (LPCVD) may be used to grow the microheater in layers. More specifically, the support layer may be deposited by LPCVD onto the build substrate (eg, silicon wafer, ceramic, eg, metal nitride, quartz or glass). Thereafter, a conductive material may be deposited on the support layer, also by LPCVD. This conductive layer may be optionally patterned to provide desired performance characteristics for the microheater. For example, reactive ion etching (REI) may be used. Electrical contact may be formed using, for example, a sputtering process to provide a means of electrical contact of the conductive material. The protective layer may be formed on the conductive layer by, for example, plasma enhanced chemical vapor deposition (PECVD). The completed microheater may be removed from the construction substrate if desired. For example, anisotropic etching with a deep REI process may be used to remove some or all of the silicon build substrate. Additionally, stacked microheaters may be packaged, for example, to provide easy access to electrical contacts, while at the same time providing additional protection for the functional components of the microheater. For example, packaging may be used to hermetically seal the microheater within a thermally stable and thermally conductive material.

Other means for preparing microheaters useful in articles of the invention may include metal evaporation processes to deposit a conductive layer onto a support layer. If desired, an adhesive layer may be placed before the metal evaporation step. Patterning of the conductive material may be performed using a photoresist by standard photolithography techniques (e.g., Shipley-1818), which include spin-coating the photoresist onto the conductive layer; soft baking (e.g., at a temperature of about 65° C.) to remove the photoresist solvent; aligning the applied photoresist, e.g., in a mask aligner; and using a UV lamp, exposing the conductive layer to light while applying pressure with a mask; developing the patterned photoresist into solution using a suitable developer (e.g., commercially available from Shipley); baking (eg, at a temperature of about 90° C.) to harden the photoresist. The previously exposed conductive material may be removed by applying a photoresist and etching with a suitable solvent. The photoresist may then be removed using a suitable solvent. Such processing may be characterized as subtractive printing, and the formed microheater may be described generally, or the conductive layer specifically, as a subtractively formed article or layer. .

Microheaters may be prepared using various printing techniques. Specifically, the conductive material may be systematically arranged in a desired pattern using inkjet printing technology. This may be particularly useful for forming a conductive layer on a support layer that may itself be relatively thin, without the need for an additional build substrate. Such techniques in which the conductive material is a printed layer laminated to a support layer may be characterized as additive manufacturing, and the formed microheater generally or the conductive layer specifically It can be described as

The foregoing processes are only examples of the types of processes that may be used to prepare microheaters for use in accordance with the present disclosure and are considered to limit the microheaters that may be used in the articles described herein. Shouldn't. Additionally, stable microheaters for use as described herein are commercially available, for example, from Kebaili Corporation (Irvine, Calif., www.kebaili.com).

In further embodiments, microheaters for use in the devices of the present disclosure may be chemical in nature. More specifically, the microheater may provide heating based on chemical reactions rather than electrical resistance heating.

The microheater used in the articles described herein may provide several advantages over the use of known heating elements. Such microheaters can provide highly energy efficient electrical heating, especially when controlled amounts of the material to be heated (eg, an aerosol precursor composition) are delivered to the microheater. This microheater can also easily achieve very precise aerosol chemistry in a controlled manner.

Smoking articles such as those described herein may generally include a power source that provides sufficient current to provide various functions to the article, e.g., microheater output, indicator output, etc. . This power source may take various embodiments. Preferably, the power source is capable of delivering sufficient power to rapidly heat the microheater to generate an aerosol and power the article through use for a desired period of time. The power source is preferably sized to conveniently fit within the article. Examples of useful power sources include lithium ion batteries, preferably rechargeable (eg, rechargeable lithium-manganese dioxide batteries). Specifically, lithium polymer batteries may be used. Other types of batteries may also be used, such as the N50-AAA CADNICA nickel-cadmium cell. Still further examples of batteries that can be used in accordance with the present invention are described in US Patent Application Publication No. 2010/0028766, the disclosure of which is incorporated herein by reference in its entirety. Thin film batteries may be used in certain embodiments of the invention. Although any of these batteries or combinations thereof may be used for the power source, rechargeable batteries are preferred due to cost and disposability considerations associated with disposable batteries. In embodiments where disposable batteries are provided, the smoking article may include access for battery removal and replacement. Alternatively, in embodiments using rechargeable batteries, the smoking article can be powered from a standard 120 volt AC wall outlet or other power source, such as an automobile's electrical system or another portable power source, such as a USB connection. A charging contact may be provided for interaction with a corresponding contact in a conventional recharging unit that extracts power. Means for recharging the battery may be provided in a portable charging case, which may provide multiple charges for relatively small batteries present in, for example, smoking articles. It may also include a battery unit. The article may further include components to provide a contactless inductive recharging system so that the article can be charged without physically connecting to an external power source. Accordingly, the article may include components that facilitate the transfer of energy from the electromagnetic field to a rechargeable battery within the article.

In further embodiments, the power source may also include a capacitor. Capacitors can be recharged more rapidly than batteries, and can be charged during a puff, allowing the battery to discharge into the capacitor at a slower rate than if the battery were used to power the heating element directly. enable. For example, a supercapacitor, ie, an electric double layer capacitor (EDLC), may be used separately from or in combination with a battery. When used alone, the supercapacitor may be recharged before each use of the article. Accordingly, the invention may also include a charging component that can be attached to the smoking article during use to replenish the supercapacitor.

The smoking article may further include various power management software, hardware, and/or other electrical control components. For example, such software, hardware and/or electronic controls may be used to charge the battery, to detect the charging and discharging conditions of the battery, to perform power saving operations, to prevent unintentional or excessive charging of the battery, etc. This may include preventing puffs, counting puffs, delimiting puffs, determining puff periods, identifying cartridge status, temperature control, and the like.

A "control device" or "control component" according to the present disclosure may include a variety of elements useful in the smoking articles of the present invention. Additionally, smoking articles according to the invention may include one, two or more control components, which may be combined into a single element or may be present at separate locations within the smoking article. Individual control components may be utilized to perform different aspects of control. For example, the smoking article may be integrated with or otherwise associated with a battery and include a control component that controls discharge from the battery. The smoking article may separately include control components that control other aspects of the article. The smoking article may also include control components in the cartridge to provide certain functions including data storage (eg, a microchip containing memory). Alternatively, a single control device may be provided that performs multiple or all control aspects of the article. Similarly, sensors used in the article (eg, puff sensors) may include control components that control the operation of discharging the power source in response to stimulation. The article may separately include control components that control other aspects of the article. Alternatively, a single control device may be provided or coupled in other ways with sensors for controlling multiple or all control aspects of the article. Accordingly, various combinations of control devices may be combined in the smoking article of the present invention to provide the desired level of control of all aspects of the device.

The smoking article may also include one or more controller components useful for controlling the flow of electrical energy from the power source to further components of the article, such as to a resistive heating element. The article may include a control component that operates electrical current from a power source to a microheater or the like. In some embodiments, the article may include a push button that may be coupled to a control circuit for manual control of power flow. The one or more push buttons may be substantially flushed on the exterior of the smoking article.

Instead of (or in addition to) push buttons, articles of the invention may include one or more control components responsive to a consumer's inhalation (i.e., puff-activated heating) at the article. For example, the article may include a switch that is sensitive to either pressure changes or changes in air flow when a consumer inhales with the article (i.e., a puff-actuated switch). ). Other current actuation/deactivation mechanisms include temperature actuated on/off switches or lip pressure actuated switches. An exemplary mechanism that may provide such puff actuation capability includes the Model 163PC01D36 silicon sensor (manufactured by MicroSwitch division of Honeywell, Inc., Freeport, Ill.). A further example of a demand-operated electrical switch that may be used in a heating circuit according to the present invention is U.S. Pat. No. 4,735,217 (Gerth et al.). Other suitable different switches, analog pressure sensors, flow rate sensors, etc. will be apparent to those skilled in the art having knowledge of this disclosure. A pressure-sensing tube or other passageway providing a fluid connection between the puff actuation switch and the air flow path within the smoking article is provided, thereby controlling pressure changes during inhalation. may be specified by the switch. Further description of current regulation circuits and other control components, including microcontrollers, that may be useful in the smoking articles of the present invention is found in U.S. Patent No. 4,922, all of which are incorporated by reference in their entirety. , 901, 4,947,874, and 4,947,875 (all to Brooks et al.), U.S. Pat. No. 5,372,148 (to McCafferty et al.), U.S. Pat. , 040,560 (to Fleischhauer et al.), and US Pat. No. 7,040,314 (to Nguyen et al.).

Capacitive sensing components, in particular, devices thereof in a variety of ways that allow for various types of "power-up" and/or "power-down" for one or more components of this apparatus. It may be incorporated into Capacitive sensing may include the use of any sensor that incorporates technology based on capacitive coupling, including, but not limited to, proximity, location or movement, humidity, Sensors that detect and/or measure liquid level, pressure, temperature or acceleration may be mentioned. Capacitive sensing can result from electrical components that provide surface capacitance, projected capacitance, mutual capacitance, or self-capacitance. Capacitive sensors can generally detect anything that is conductive or has a dielectric other than air. For example, a capacitive sensor may replace a mechanical button (ie, the pushbutton mentioned above) with a capacitive alternative. One particular application of the capacitive sensor according to the invention is therefore a touch capacitive sensor. For example, a touch pad may be present on the smoking article, which allows the user to enter various commands. Most basically, this touchpad can power the heating element in the same way as a pushbutton, as already described above. In other embodiments, capacitive sensing may be provided near the mouth end of the smoking article, such that the pressure of the lips against the smoking article to draw on the article is a power source against the heating element. may be signaled to a device that provides. In addition to touch capacitive sensors, motion capacitive sensors, liquid capacitive sensors, and acceleration sensors may be utilized in accordance with the present invention to elicit various responses from smoking articles. Additionally, optoelectronic sensors may also be incorporated into the smoking articles of the present invention.

The sensors utilized in the articles of the invention can specifically signal for the flow of electrical power to the heating element, thereby heating the aerosol precursor composition and producing vapor or aerosol for inhalation by the user. form. Sensors may also provide additional functionality. For example, a "wake-up" sensor may be provided. Other sensing methods providing similar functionality may be utilized as well.

When a consumer inhales at the mouth end of the smoking article, the current actuated means can enable unrestricted or uninterrupted flow of current through the resistive heating member to rapidly generate heat. It may be useful to include a current adjustment component to adjust the flow of current through the microheater to control the heating rate and/or duration.

The current regulation circuit may in particular be time-based. Specifically, such a circuit includes means for allowing uninterrupted current flow through the heating element over an initial period during inhalation and for continuing current flow until inhalation is complete. and timer means for adjusting. Additionally, regulation may involve simply allowing uninterrupted current flow until the desired temperature is achieved and then completely shutting off the current. This heating element activates another puff (or manually actuates a push button, depending on the particular switch embodiment used to activate the heater) for this article. It can be restarted by the user. Alternatively, subsequent adjustments may include adjusting the flow of current through the heating element (including pulse width adjustment) to maintain the heating element within a desired temperature range. In some embodiments, the heating member is applied for about 0.2 seconds to about 5.0 seconds, about 0.3 seconds to about 4.5 seconds, about 0 seconds to release the desired dose of the inhalable substance. Energy may be delivered over a period of .5 seconds to about 4.0 seconds, about 0.5 seconds to about 3.5 seconds, or about 0.6 seconds to about 3.0 seconds. Further descriptions of such timed current regulation circuits and other control components that may be useful in the smoking articles of the present invention are provided by Brooks No. 4,922,901, US Pat. No. 4,947,874, and US Pat. No. 4,947,875 to et al.

The control component may be specifically configured to closely control the amount of heat provided to the microheater. In some embodiments, the current regulating component may function to stop the current to the microheater once a predetermined temperature is reached. Such predetermined temperature may be in a range substantially high enough to volatilize the aerosol precursor composition and any additional inhalable substances and provide a quantity of aerosol at the desired concentration. The heat required to volatilize the aerosol precursor composition can vary, but heating to a temperature of about 120°C or higher, about 130°C or higher, about 140°C or higher, or about 160°C or higher is suitable for microheaters. It may be particularly useful. In some embodiments, the heating temperature may be about 180°C or higher, about 200°C or higher, about 300°C or higher, or about 350°C or higher to volatilize the desired amount of the aerosol precursor composition. good. In further embodiments, the prescribed temperature for aerosol formation may be from about 120°C to about 350°C, from about 140°C to about 300°C, or from about 150°C to about 250°C. The temperature and time of heating may be controlled by one or more components included in the housing of the controller. The current regulating component may similarly cycle the current to the microheater off and on to maintain the specified temperature for a specified period of time once a predetermined temperature is achieved.

Additionally, the current regulating component cycles the current to the microheater off and on to maintain an initial temperature below the aerosol formation temperature and then responds to the current actuated control component to increase the current. A second temperature may be achieved which is greater than the first temperature and is an aerosol formation temperature. Such control improves the response time of the article for aerosol formation so that aerosol formation begins almost immediately upon initiation of puffing by the consumer. In some embodiments, the initial temperature (which may be characterized as a standby temperature) may be only slightly lower than the aerosol forming temperature defined above. Specifically, the standby temperature may be about 50°C to about 150°C, about 70°C to about 140°C, about 80°C to about 120°C, or about 90°C to about 110°C.

In addition to the above elements, the smoking article may also include one or more indicators. Such an indicator may be a light (eg, a light emitting diode), which can provide an indication of numerous aspects of use of the article of the invention. Additionally, an LED indicator may be placed on the tip of the smoking article to simulate the color change seen when a conventional cigarette lights up and is smoked by a user. Other operational indicators are also included. For example, visual indicators may also include changes in the color or intensity of the light to indicate the progression of the smoking experience. Tactile and audible indicators are also encompassed by the present invention. Additionally, combinations of such indicators may also be used in a single article.

In certain embodiments, smoking articles according to the invention include tobacco, tobacco components, or tobacco-derived materials (i.e., materials naturally found in tobacco, whether isolated directly from tobacco, or synthetic materials). (which may be prepared manually). Tobaccos used include hot air-cured tobacco, burley tobacco, Oriental tobacco, Maryland tobacco, dark tobacco, dark-fired tobacco, and rustica ( Rustica tobacco, as well as other rare or specialty tobaccos, or blends thereof. Various representative tobacco types, processed tobacco types, and tobacco blend types are described in US Pat. No. 4,836,224 to Lawson et al.; US Pat. No. 4,924,888 to Perfetti et al.; U.S. Patent No. 5,056,537; U.S. Patent No. 5,159,942 to Brinkley et al.; U.S. Patent No. 5,220,930 to Gentry; U.S. Patent No. 5,360,023 to Blakley et al.; Shafer et al. U.S. Patent No. 6,701,936 to Dominguez et al., U.S. Patent No. 6,730,832 to Li et al., U.S. Patent No. 7,011,096 to Li et al.; US Pat. No. 7,025,066 to Lawson et al.; US Patent Application Publication No. 2004/0255965 to Perfetti et al.; WO 02/37990 to Bereman; and Bombick et al., Fund. Appl. Toxicol. , 39, p. 11-17 (1997), the disclosures of which are incorporated herein by reference in their entirety.

Tobacco incorporated into smoking articles may be used in a variety of forms. Combinations of various forms of tobacco may be used or different forms of tobacco may be used at different locations within the smoking article. For example, tobacco may be used in the form of tobacco extract. See, e.g., U.S. Patent No. 7,647,932 to Cantrell et al. thing.

Smoking articles may incorporate tobacco additives of the type traditionally used in the manufacture of tobacco products. These additives may include materials of the type used to enhance the flavor and aroma of tobacco used to produce cigars, cigarettes, pipes, etc. For example, these additives can include components of various cigarette shells and/or top layers. See, for example, U.S. Pat. No. 3,419,015 to Wochnowski; U.S. Pat. No. 4,054,145 to Berndt et al.; Burcham, Jr. U.S. Pat. No. 4,887,619 to Watson 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. (the disclosures of which are hereby incorporated by reference in their entirety). Preferred shell materials include water, sugars and syrups (eg, sucrose, glycol and high fructose corn syrup), humectants (eg, glycerin or propylene glycol), and flavorings (eg, cocoa and licorice). Those added ingredients also include top layer materials (eg, flavorants, eg, menthol). See, eg, US Pat. No. 4,449,541 to Mays et al., the disclosures of which are incorporated herein by reference in their entirety. Additional materials that may be added include U.S. Patent No. 4,830,028 to Lawson et al. and U.S. Patent Application Publication No. 2008/0245377 to Marshall et al. Examples include materials disclosed in

Various schemes and methods for incorporating tobacco into smoking articles, specifically those designed to intentionally avoid burning substantially all of the tobacco within those smoking articles, are described in the US publication by Brooks et al. No. 4,947,874; U.S. Patent No. 7,647,932 to Cantrell et al., U.S. Patent Application Publication No. 2005/0016549 to Banerjee et al.; and U.S. Patent Application Publication No. 2007/0215167 to Crooks et al. (the disclosure of which is hereby incorporated by reference in its entirety).

Additional tobacco materials may be included in the vapor or aerosol precursor composition, such as tobacco aroma oil, tobacco essence, spray-dried tobacco extract, freeze-dried tobacco extract, tobacco dust, and the like. As used herein, the term "tobacco extract" means a component that is separated from, extracted from, or derived from tobacco using tobacco extraction processing conditions and techniques. do. Specifically, purified extracts of tobacco or other plants may be used. Typically, tobacco extracts are obtained using a solvent such as a solvent of aqueous nature (eg, water) or an organic solvent (eg, alcohols such as ethanol, or alkanes such as hexane). Thus, extracted tobacco components are removed from the tobacco and separated from unextracted tobacco components; and for extracted tobacco components present in a solvent, (i) the solvent is separated from the extracted tobacco components; Even if removed, (ii) the mixture of extracted tobacco components and solvent may be used as such. Exemplary types of tobacco extracts, tobacco extracts, solvents, tobacco extraction processing conditions and techniques, and tobacco extract collection and isolation procedures are described in Australian Patent No. 276,250 to Schachner; US Pat. No. 805,669; U.S. Pat. No. 3,316,919 to Green et al.; U.S. Pat. No. 3,398,754 to Tughan; U.S. Pat. No. 3,424,171 to Rooker; U.S. Pat. , 118; US Pat. No. 4,150,677 to Osborne; US Pat. No. 4,131,117 to Kite; US Pat. No. 4,506,682 to Muller; US Pat. No. 4,986, to Roberts et al. US Pat. No. 5,005,593 to Fagg; US Pat. No. 5,065,775 to Fagg; US Pat. No. 5,060,669 to White et al.; US Pat. No. 5,074 to White et al. No. 319; U.S. Patent No. 5,099,862 to White et al.; U.S. Patent No. 5,121,757 to White et al.; U.S. Patent No. 5,131,415 to Munoz et al.; No. 230,354; U.S. Patent No. 5,235,992 to Sensabaugh; U.S. Patent No. 5,243,999 to Smith; U.S. Patent No. 5,301,694 to Raymond; U.S. Patent No. 5 to Gonzalez-Parra et al. , 318,050; US Pat. No. 5,435,325 to Clapp et al.; and US Pat. No. 5,445,169 to Brinkley et al., the disclosures of which are incorporated herein by reference in their entirety. ) is shown.

The aerosol or vapor precursor composition may include one or more different components. For example, the aerosol precursor may include a polyhydric alcohol (eg, glycerin, propylene glycol or mixtures thereof). Additional representative types of aerosol precursor compositions are described by Sensabaugh, Jr. U.S. Patent No. 4,793,365 to Jakob et al.; U.S. Patent No. 5,101,839 to Jakob et al.; PCT WO 98/57556 to Biggs et al.; Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988), the disclosure of which is incorporated herein by reference. In some embodiments, the aerosol precursor composition produces a visible aerosol upon application of sufficient heat thereto (and optionally cooling with air), and the aerosol precursor composition Aerosols may be produced, which can be considered "smoke-like." In other embodiments, the aerosol precursor composition may produce an aerosol that is substantially invisible, but may be recognized as present by other characteristics such as flavor or texture. Accordingly, the properties of the aerosol produced may vary depending on the particular components of the aerosol precursor composition. This aerosol precursor composition may be chemically simpler than the smoke chemistry produced by burning tobacco.

The aerosol precursor composition may include additional liquid substances such as water. For example, the aerosol precursor composition may incorporate a mixture of glycerin and water, or a mixture of propylene glycol and water, or a mixture of propylene glycol and glycerin, or a mixture of propylene glycol, glycerin and water. Exemplary aerosol precursor compositions also include electronic cigarettes under the trade name E-CIG, which can be used with associated smoking cartridge types C1a, C2a, C3a, C4a, C1b, C2b, C3b and C4b. Atlanta Imports Inc. , Acworth, Ga. , USA. and as Ruyan Atomizing Electronic Pipe and Ruyan Atomizing Electronic Cigarette, Ruyan SBT Technology and Development. Co. , Ltd. , Beijing, China. These include the types of materials that are incorporated into devices available from.

Aerosol precursor compositions used in the disclosed articles may further include one or more flavors, drugs, or other inhalable substances. For example, liquid nicotine may be used. Such additional materials may include one or more components of an aerosol precursor or vapor precursor composition. Accordingly, an aerosol precursor or vapor precursor composition may be described as comprising an inhalable substance. Such inhalable substances may include flavors, drugs, and other substances described herein. In particular, the inhalable substances delivered using smoking articles according to the invention may include tobacco components or substances derived from tobacco. Alternatively, the flavor, drug, or other inhalable substance may be provided separately from other aerosol precursor components, eg, in a reservoir. Thus, a defined amount of flavorant, drug, or other inhalable substance is present in the stream of air inhaled by the user along with further components of the aerosol precursor or vapor precursor composition. It may be delivered separately or simultaneously to a resistive heating element for releasing other inhalable substances. Alternatively, the flavoring agent, drug, or other inhalable substance may be provided in a separate part of the smoking article or component thereof. In certain embodiments, the flavorant, drug, or other inhalable substance may be deposited onto a substrate (eg, paper or other porous material) that is placed near the microheater. Preferably close enough so that the heating of the microheater provides sufficient heat to volatilize and release flavorants, drugs, or other inhalable substances from the substrate.

A wide variety of flavoring agents or substances that modify the sensory or organoleptic characteristics or properties of the mainstream aerosol of the smoking article may be used. Such flavoring agents may be obtained from sources other than tobacco, may be natural or artificial in nature, and may be used as concentrates or flavor packages. Of particular interest are flavoring agents that are added to or incorporated into the area of the smoking article where the aerosol is generated. Again, such agents may be supplied directly to the resistive heating element, as already mentioned above, or provided to the substrate. Exemplary flavorants include vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors including lime and lemon), maple, menthol, mint, peppermint, Spearmint, wintergreen, nutmeg, cloves, lavender, cardamom, ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, and traditionally used to flavor tobacco in cigarettes, cigars, and pipes. These include flavorings and flavoring packages of different types and characteristics. Syrups, such as high fructose corn syrup, may also be used. Flavoring agents may also contain acidic or basic characteristics, such as organic acids such as levulinic acid, succinic acid, lactic acid and pyruvic acid. This flavoring agent may optionally be combined with the aerosol product. Exemplary plant-based compositions that may be used are disclosed in U.S. Patent Application No. 12/971,746 to Dube et al. and U.S. Patent Application No. 13/015,744 to Dube et al. , incorporated herein by reference in its entirety.

Organic acids may be specifically incorporated into the aerosol precursor to influence the flavor, sensory or organoleptic properties of the drug, such as nicotine, that may be combined with the aerosol precursor. For example, organic acids such as levulinic acid, succinic acid, lactic acid and pyruvic acid may be included in the aerosol precursor together with nicotine in amounts up to equimolar with nicotine (based on the total organic acid content). Any combination of organic acids may be used. For example, the aerosol precursor may include about 0.1 to about 0.5 moles of levulinic acid per mole of nicotine, about 0.1 to about 0.5 moles of pyruvic acid per mole of nicotine, and about 0.1 to about 0.5 moles of pyruvic acid per mole of nicotine. 1 to about 0.5 moles of lactic acid, or combinations thereof, may be included at a concentration where the total amount of organic acids present is up to equimolar to the total amount of nicotine present in the aerosol precursor.

Aerosol precursor compositions may take various forms based on the various amounts of materials utilized herein. For example, useful aerosol precursor compositions may include up to about 98%, up to about 95%, or up to about 90% by weight polyol. This total amount may be divided in any combination between two or more different polyols. For example, one polyol may include about 50% to about 90%, about 60% to about 90%, or about 75% to about 90% by weight of the aerosol precursor, and the second polyol may include about 2% by weight of the aerosol precursor. % to about 45%, about 2% to about 25%, or about 2% to about 10% by weight of the aerosol precursor. Useful aerosol precursors also include about 25%, about 20% or about 15% water, particularly about 2% to about 25%, about 5% to about 20%, or about 7% to about 15% by weight. % of water. Flavoring agents and the like (which may include drugs such as nicotine) may include up to about 10%, up to about 8%, or up to about 5% by weight of the aerosol precursor.

As a non-limiting example, an aerosol precursor according to the invention may include glycerol, propylene glycol, water, nicotine, and one or more flavorants. Specifically, the glycerol may be present in an amount of about 70% to about 90%, about 70% to about 85%, or about 75% to about 85% by weight; Water may be present in an amount of 1% to about 10%, about 1% to about 8%, or about 2% to about 6% by weight, and water is about 10% to about 20%, about 10% by weight. nicotine may be present in an amount of from about 0.1% to about 5%, from about 0.5% to about 4%, or from about 0.1% to about 4% by weight, or from about 12% to about 16% by weight; The flavoring agent may be present in an amount of about 1% to about 3% by weight, and the flavoring agent may be present in an amount of up to about 5%, up to about 3%, or up to about 1% by weight; Amounts are based on the total weight of aerosol precursor. One specific non-limiting example of an aerosol precursor is about 75% to about 80% by weight glycerol, about 13% to about 15% by weight water, about 4% to about 6% by weight propylene glycol, about 2% to about 3% by weight nicotine, and about 0.1% to about 0.5% by weight flavor. The nicotine may be, for example, a high nicotine content tobacco extract.

The amount of aerosol precursor composition used in a smoking article is such that the article exhibits acceptable sensory and organoleptic properties as well as desirable performance characteristics. For example, sufficient aerosol precursor composition components, such as glycerin and/or propylene glycol, may be used to produce a mainstream aerosol that visually closely resembles the appearance of cigarette smoke. Typically, the amount of aerosol-generating material incorporated into the smoking article ranges from about 1.5 g or less, about 1 g or less, or about 0.5 g or less. The amount of aerosol precursor composition may depend on factors such as the desired number of puffs per cartridge used with the smoking article. The aerosol-generating composition may result in unacceptable taste abnormalities, mouth sensations such as a thin film, or an overall It is desirable not to significantly induce sensory experience. In particular, the selection of aerosol generating and reservoir materials, the amounts of ingredients used, and the type of tobacco material used may be varied to control the overall chemical composition of the mainstream aerosol produced by the smoking article.

Beneficially, the microheater may be placed in close contact with or near the aerosol precursor composition. In other embodiments, the microheater may be at a location within the article such that an aerosol precursor composition can be delivered to the microheater for aerosolization. For example, the aerosol precursor composition (or its components) may be delivered via capillary action through a wick or other porous material, or by active or passive flow (which may include control of valves), etc. , may be provided in liquid form to allow flow of the composition from one or more reservoirs to the microheater. Accordingly, the aerosol precursor composition may be provided in liquid form in one or more reservoirs located sufficiently far from the microheater to prevent premature aerosolization, but to prevent transport of the aerosol precursor composition. The microheater may be placed in any desired amount close enough to the microheater to facilitate aerosolization. Alternatively, the aerosol precursor composition may be at least partially saturated within the substrate, which may be brought into direct contact with the microheater, such that upon heating, the aerosol precursor composition is released from the substrate. Ru. Still further, the aerosol precursor composition may be in the form of a foam, gel or solid. The physical state of the aerosol precursor composition may be the state of the material at ambient conditions (eg, temperature and pressure). Such embodiments in particular allow precise aliquoting of the aerosol precursor material provided in contact with the microheater, thereby obtaining a defined number of puffs. Such embodiments are discussed in further detail elsewhere herein.

The amount of aerosol emitted by articles of the invention can vary. Preferably, the article contains a sufficient amount of the aerosol precursor composition and a sufficient amount to function at a sufficient temperature for a sufficient time to release the desired content of aerosolized material over the course of use. and any further inhalable substance. This content may be delivered in a single inhalation from the article over a relatively short period of time (e.g., less than 30 minutes, less than 20 minutes, less than 15 minutes, less than 10 minutes, or less than 5 minutes). It may be divided to be served through multiple puffs. For example, the article may contain nicotine in an amount of about 0.01 mg to about 0.5 mg, about 0.05 mg to about 0.3 mg, or about 0.1 mg to about 0.2 mg per puff of the article. can be provided. For calculation purposes, an average puff time of about 2 seconds can deliver a puff volume of about 5 ml to about 100 ml, about 15 ml to about 70 ml, about 20 ml to about 60 ml, or about 25 ml to about 50 ml. Such total puff volume may, in certain embodiments, provide the previously described WTPM content. Smoking articles according to the invention may be configured to provide any number of puffs that can be calculated by dividing the total amount of aerosol or other inhalable substance delivered by the amount delivered per puff. . One or more reservoirs may be filled with an appropriate amount of aerosol precursor or other inhalable substance to achieve a desired number of puffs and/or a desired total amount of substance delivered.

In further embodiments, the heating may be characterized with respect to the amount of aerosol to be generated. Specifically, the article contains a defined volume of aerosol (e.g., from about 5 ml to about 100 ml, or any other volume deemed useful in a smoking article, such as those described elsewhere herein). may be configured to obtain the amount of heat necessary to produce. In certain embodiments, the amount of heat generated can be measured for a 2-4 second puff, providing about 35 ml of aerosol at a heater temperature of about 290°C. In some embodiments, the article preferably has about 1 to about 50 joules per second (J/s), about 2 J/s to about 40 J/s, about 3 J/s to about 35 J/s, or about Heat from 5 J/s to about 30 J/s can be provided.

The microheater is preferably electrically connected to a power source of the smoking article such that electrical energy is provided to the microheater to generate heat and subsequently aerosolize the aerosol precursor composition and its various components. You may. Such electrical connections may be permanent (e.g., hard-wired) or removable (e.g., where the microheater is connected in a removable cartridge from a control body with a power source. ).

Although various materials have been described above for use in smoking articles according to the present invention (e.g., heaters, batteries, capacitors, switching components, reservoirs, dispensers, aerosol precursors, etc.), the present invention is not limited to exemplary materials. The invention should not be construed as limited only to the specific embodiments. Those skilled in the art will recognize, based on this disclosure, similar components in the field that may be interchangeable with any particular component of the present invention. For example, Sprinkel, Jr. No. 5,261,424 to discloses a piezoelectric sensor that may be associated with the mouth end of a device that detects movements of a user's lips associated with performing an inhalation and then induces heating. US Pat. No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow to a heated load array in response to a pressure drop through a mouthpiece; US Pat. No. 967,148 discloses a container in a smoking device comprising an identifier for detecting non-uniformity in infrared transmittance of an inserted component and a control device that performs a detection operation as the component is inserted into the container. US Patent No. 6,040,560 to Fleischhauer et al. describes a defined viable power cycle with a number of different stages; US Patent No. 5,934,289 to Watkins et al. Discloses photonic-optronic components; U.S. Pat. No. 5,954,979 to Counts et al. discloses means for varying inhalation resistance by a smoking device; U.S. Patent No. 5,954,979 to Counts et al. Patent No. 6,803,545 discloses a particular battery configuration for use in a smoking device; U.S. Patent No. 7,293,565 to Griffin et al. Discloses various charging systems; US Patent Application Publication No. 2009/0320863 to Fernando et al. discloses computer interface means for a smoking device that facilitates charging and allows computer control of the device; Fernando et al. U.S. Pat. all of the foregoing disclosures are incorporated herein by reference in their entirety. Further examples of components for electronic aerosol delivery articles and disclosed materials or components that may be used in articles of the present invention include U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. No. 5,249,586; U.S. Patent No. 5,666,977 to Higgins et al.; U.S. Patent No. 6,053,176 to Adams et al.; U.S. Patent No. 6,164,287 to White; No. 6,196,218; U.S. Patent No. 6,810,883 to Felter et al.; U.S. Patent No. 6,854,461 to Nichols; U.S. Patent No. 7,832,410 to Hon; U.S. Patent No. 7 to Kobayashi , 513,253; U.S. Patent No. 7,896,006 to Hamano; U.S. Patent No. 6,772,756 to Shayan; U.S. Pat. 2009/0126745 and 2009/0188490; U.S. Patent Application Publication No. 2009/0272379 to Thorens et al.; U.S. Patent Application Publication No. 2009/0260641 and 2009/0260642 to Monsees et al.; US 2008/0149118 and 2010/0024834; US 2010/0307518 to Wang; and WO 2010/091593 to Hon. The various materials disclosed in the aforementioned documents may be incorporated in various embodiments into the devices of the present invention, all of the aforementioned disclosures being incorporated herein by reference in their entirety.

Although the article according to the invention may take on a variety of embodiments, as discussed in detail below, the use of the article by a consumer is similar within scope. In particular, the article may be provided as a single unit or as multiple components that are assembled by the consumer for use and then disassembled by the consumer. In general, smoking articles according to the invention may include a first unit that is engageable and releasable with a second unit, the first unit including a resistive heating element, and the second unit being engageable and releasable. The unit is equipped with a power supply. In some embodiments, the second unit may further include one or more control components that actuate or regulate electrical current from the power source. This first unit may have a distal end that mates with the second unit and an opposing proximal end with an open mouthpiece (or simply a mouth end) at its proximal end. The first unit may include an air flow path opening to the mouthpiece of the first unit, the air flow path being for passage of aerosol formed from the resistive heating element into the mouthpiece. can be provided. In preferred embodiments, this first unit may be disposable. Similarly, the second unit may be reusable.

A smoking article according to the invention may have a reusable control body that is substantially cylindrical in shape, having a connecting end and an opposing closed end. The closed end of the control housing may include one or more indicators of active use of the article. The article may include a cartridge with a connecting end that engages a connecting end of the control body and with an opposing mouth end. In use, the consumer may connect the connecting end of the cartridge to the connecting end of the control body, or otherwise combine the cartridge and the control body, thereby making the article as discussed herein. become operational as specified. In some embodiments, the control body and the connecting end of the cartridge may be attached with a threaded engagement. In other embodiments, the connecting end may have a press-fit engagement.

During use, the consumer initiates heating of the resistive heating element and the heat generated by the resistive heating element aerosolizes the aerosol precursor composition and optionally further inhalable material. do. Such heating releases at least a portion of the aerosol precursor composition in the form of an aerosol (which may include any additional inhalable substances contained therein), and such aerosol is Provided within a space inside the cartridge in fluid communication with the mouth end of the cartridge. When a consumer inhales at the mouth end of a cartridge, air is drawn through the cartridge and the combination of the breathed air and aerosol is such that the inhaled material is transferred to the mouth end of the cartridge (any mouthpiece present). ) and towards the consumer's mouth, it is inhaled by the consumer. To initiate heating, the consumer may activate a pushbutton, capacitive sensor, or similar component, whereby the resistive heating element is connected to a battery or other energy source (e.g., a capacitor). ) receives electrical energy from This electrical energy may be supplied for a predetermined length of time or may be manually controlled. Preferably, the flow of electrical energy does not proceed substantially during puffing with the article (the flow of energy does not proceed to rapidly bring the baseline temperature down to ambient temperature - e.g., the active heating temperature). (although it may be maintained higher than the temperature that facilitates proper heating). In further embodiments, heating may be initiated by the consumer's puffing behavior through the use of various sensors, as described elsewhere herein. Once puffing is interrupted, heating is stopped or reduced. If the consumer performs a sufficient number of puffs, thereby releasing a sufficient amount of inhalable material (e.g., an amount sufficient to equal a typical smoking experience), the cartridge will release from the control housing. It may be removed and discarded. An indication may be provided that the cartridge has been consumed (ie, the aerosol precursor composition has been substantially consumed by the consumer). In some embodiments, a single cartridge may provide more than one smoking experience, thereby providing sufficient content of the aerosol precursor composition to be equivalent to a full pack of conventional cigarettes or more. It can be simulated to some extent.

The foregoing description of the use of this article can be applied to the various embodiments described with minor modifications that may be apparent to those skilled in the art in view of the further disclosure provided herein. However, the above description of use is not intended to limit the use of the article of the invention, but is presented to comply with all essential requirements of the present disclosure.

Referring now to FIG. 2, a smoking article 10 according to the present invention may generally include a shell 15 and a plurality of components disposed within the shell. The article may be characterized as having a mouth end 11 (i.e., at which the consumer can inhale aerosol from the article) and a tip end 12 . The illustrated article is provided as a single unit device (although the line at A is an arbitrary boundary by which the device can be separated into two separate components, which , denoting boundaries, removably or permanently attached together, such as by gluing). As will be apparent from the further disclosure herein, further embodiments of this article are preferably formed from two or more combinable units, each housing another component of the article. There are cases. The various components shown in the embodiment of FIG. 2 may be present in other embodiments, including embodiments formed from multiple units.

Article 10 may have an overall shape that may be defined as being substantially rod-shaped, or substantially tubular in shape, or substantially cylindrical in shape. As shown in FIG. 2, the article has a substantially round cross-section; however, other cross-sectional shapes (eg, oval, square, triangular, etc.) are also encompassed by the present disclosure. This term, which is indicative of the physical form of the article, may also apply to individual units of the article in embodiments comprising multiple units, such as a control body and a cartridge.

The shell 15 of the smoking article 10 may be formed from any material suitable for forming and maintaining the appropriate conformation, such as a tubular shape, and for retaining the appropriate components of the article therein. good. This shell may be formed from a single wall as shown in FIG. In some embodiments, the shell is heat resistant, thereby retaining its structural integrity (e.g., at least the heating temperature provided by a resistive heating element, as discussed further below). may be formed from materials (natural or synthetic) that do not decompose at temperatures of In some embodiments, the high temperature polymer or metal (eg, stainless steel) may be used. In other embodiments, the shell may be formed from paper, such as substantially straw-shaped paper. A shell, such as a paper tube, may have one or more layers associated therewith that function to substantially impede the movement of vapor therethrough. In one embodiment, a layer of aluminum foil may be laminated to one side of the shell. Ceramic materials may also be used.

In further embodiments, smoking articles according to the invention may include various materials that may provide specific functions. For example, the shell 15 may include an overlap over at least a portion thereof, such as at the mouth end of the article, and such overlap may also be formed from multiple layers. . This overwrap may be, for example, a typical wrapper for cigarettes. This overwrap may particularly include materials typically used in conventional cigarette filter elements, such as cellulose acetate, and thereby function to provide a conventional cigarette feel in the consumer's mouth. Exemplary types of packaging materials, packaging material components, and treated packaging materials that may be used in the overwraps of the present invention include U.S. Pat. No. 5,105,838 to White et al.; U.S. Pat. No. 5,271,419; US Patent No. 5,220,930 to Gentry; US Patent No. 6,908,874 to Woodhead et al.; US Patent No. 6,929,013 to Ashcraft et al.; US Patent No. 6,929,013 to Hancock et al. No. 7,195,019; U.S. Patent No. 7,276,120 to Holmes; U.S. Patent No. 7,275,548 to Hancock et al.; PCT WO 01/08514 to Fournier et al.; and PCT WO 03 to Hajaligol et al. 043450, the disclosure of which is incorporated herein by reference in its entirety. Typical packaging materials are available from Schweitzer-Maudit International to R.M. J. Reynolds Tobacco Company grades 119, 170, 419, 453, 454, 456, 465, 466, 490, 525, 535, 557, 652, 664, 672, 676 and 680.

One or more layers of non-porous cigarette paper may be used to wrap the article (with or without the presence of an overlap). An example of a suitable non-porous cigarette paper is available from Kimberly-Clark Corp. commercially available as KC-63-5, P878-5, P878-16-2 and 780-63-5. This overlap (or shell if no overlap is present) may include a resilient paperboard material, foil-lined paperboard, metal, polymeric material, foam, nanofiber web, etc. The material may be restrained by a cigarette paper wrap. The article may include tipping paper to constrain the article and optionally may be used to bind filter material to the article.

As can be seen from the embodiment of FIG. 2, smoking article 10 includes an electronic control component 20, a flow sensor 30, and a battery 40, which components are arranged in various orders within the article. Good too. Although not explicitly shown, article 10 includes the wiring necessary to provide power from battery 40 to further components and for proper operation of the necessary functions provided by this article. It is understood that wiring necessary to interconnect the components may be provided. The article 10 may further include a microheater 50 as described herein. The microheater may be electrically connected to the battery 40 through suitable wiring that facilitates the formation of a closed electrical circuit by the current flowing through the microheater. Additional wiring (not shown) may be included to obtain the necessary electrical connections within the article. In certain embodiments, the article 10 is configured such that the control component 20 receives energy from the battery 40 to energize the microheater 50 according to one or more predetermined algorithms, including pulse width adjustment, as already described above. It may be wired with electrical circuitry to deliver, control, or otherwise regulate electrical power. Such electrical circuitry may particularly incorporate a flow sensor 30 such that it is only active at the point of use of the article 10 by the consumer. For example, if a consumer puffs on the article 10, the flow sensor detects the puff and the control component 20 is then activated to provide power directly through the article so that the microheater 50 produces heat. This provides an aerosol for inhalation by the consumer. This control algorithm requires the microheater 50 to power the circuit so that a specified temperature can be maintained. Accordingly, the control algorithm may be programmed to automatically shut down the article 10 and cut off the flow of power through the article after a predetermined time delay without inflating by the consumer. Additionally, the article may include a temperature sensor to provide feedback to the control components. Such a sensor may be in direct contact with the microheater 50, for example. Other temperature sensing means may be used as well, such as relying on logic control components to increase resistance through a resistive heating element and relate such resistance to the temperature of this element. In other embodiments, flow sensor 30 is replaced by suitable components to provide alternative sensing means, such as capacitive sensing, as described elsewhere herein. Good too. Any of a variety of sensors and combinations thereof may be incorporated as previously described herein. Still further, it allows for manual actuation by the consumer to trigger various functions, such as turning power on and off to article 10, turning on microheater 50 to produce vapor or aerosol for inhalation. One or more control buttons 16 may also be provided.

Additionally, the article may include one or more status indicators 19 located on the shell 15. Such an indicator may indicate the number of puffs made or remaining on the item, as described above, it may be an indicator of activity or inactivity, or it may light up in response to a puff. For example, it is good. Although six indicators are shown, more or fewer indicators may be present, and the indicators may take different shapes and orientations, or even simply be openings in the shell (e.g., this (for sound emission if such an indicator is present).

As shown in the embodiment of FIG. 2, a reservoir 205, illustrated as a container, is shown proximate to the microheater 50, and a transfer element 300 is arranged so that the aerosol precursor composition can be delivered to the microheater for aerosolization. , from the reservoir 205 and sufficiently close to the microheater. The formed aerosol is then inhaled by the user through the mouth end 11 of the smoking article 10. The aerosol precursor composition that is aerosolized by heating the microheater may be continuously replenished (e.g., through a wick or other flow of the aerosol precursor composition from the reservoir to the microheater via a transfer element). ), or specific aliquots of the aerosol precursor composition may be delivered to the microheater on demand. This cycle continues until substantially all of the aerosol precursor composition has been aerosolized.

As can be seen from the embodiment of Figure 2, the mouth end 11 of the article 10 is a substantially open cavity in which the microheater 50 and the reservoir 205 are arranged. Such an open cavity provides a volume for the release of the aerosol formed by the microheater. The article also includes a mouth opening 18 in the mouth end 11 to allow withdrawal of aerosol from this cavity. Although not explicitly shown in the diagram of FIG. 2, the article may increase its structural integrity and/or optionally provide filtration capacity and/or create resistance to inhalation. For this purpose, it may be provided with a filter material (eg cellulose acetate or polypropylene) at its mouth end. For example, articles according to the invention may exhibit a water pressure drop of about 50-250 mm at 17.5 cc per second of air flow. In further embodiments, the pressure drop may be from about 60 mm to about 180 mm, or from about 70 mm to about 150 mm. Pressure drop values are available from the Filtrona Filter Test Station (CTS Series) available from Filtrona Instruments and Automation Ltd or Cerulean Division of Molins, PLC. It can be measured using the Quality Test Module (QTM). To facilitate the flow of air through the article, an air intake 17 may be provided, which essentially comprises an opening in the shell 15 that allows air to flow into the interior of the article. Good too. Multiple air intakes may be provided, the air intakes being such that air from the air intakes interacts with the formed aerosol and its removal from the cavity of the article and through the mouth end opening. It may be placed anywhere upstream from the mouth end of the article to facilitate.

In other embodiments, the reservoir may be a substrate adapted to hold an aerosol precursor composition, such as a layer of material that is at least partially saturated with the aerosol precursor composition. There may be. Such layers may be absorbent, adsorptive, or otherwise porous, thereby providing the ability to retain the aerosol precursor composition. Accordingly, the aerosol precursor composition may be characterized as being coated onto, adsorbed onto, or absorbed into a carrier material (or substrate), which includes one or more microheaters. may form all or a portion of the substrate material which may also carry. The carrier material may be placed within the article in substantial contact with one or more microheaters (ie, multiple microheaters).

As shown in FIG. 2, reservoir 205 may be a container formed from one or more walls defining an interior volume in which the aerosol precursor composition or one or more components thereof is stored. . The container may be formed of substantially rigid walls, and transfer of the aerosol precursor material therefrom may proceed by active or passive transfer methods as discussed herein. Alternatively, the container may be formed from a substantially plastic material so that the container can be compressed (ie, from the airbag reservoir) to facilitate transfer of the aerosol precursor material therefrom.

In a preferred embodiment, the article may have a size comparable to that of a cigarette or cigar. Thus, the article may have a diameter of about 5 mm to about 25 mm, about 5 mm to about 20 mm, about 6 mm to about 15 mm, or about 6 mm to about 10 mm. Such dimensions may correspond in particular to the outer diameter of this shell.

The embodiment smoking article 10 illustrated in FIG. 2 may be characterized as a disposable article. Therefore, it may be desirable for the reservoir containing the aerosol precursor composition in such embodiments to contain a sufficient amount of the aerosol precursor composition to allow the consumer to use the article more than once. For example, the article may be substantially equal to the number of puffs (durations of about 2 to 4 seconds) possible from a plurality of conventional cigarettes (e.g., 2 or more, 5 or more, 10 or more, or 20 or more conventional cigarettes). The article may include sufficient aerosolizable and/or inhalable material to provide an equivalent number of puffs. More specifically, the disposable single unit article according to the embodiment of FIG. 2 may provide about 20 or more, about 50 or more, or about 100 or more puffs (a single puff is defined as (measured as previously described in the book).

In some embodiments, the articles described herein may include two units that are removable from each other. For example, FIG. 3 depicts one embodiment of a smoking article 10 formed from a control body 80 and a cartridge 90. In certain embodiments, the control body may be said to be reusable and the cartridge may be said to be disposable. In some embodiments, the entire article is characterized as disposable in that the control body has a limited number of cartridges and can be configured for only a limited number of uses. (e.g., until the battery power component no longer provides sufficient power to the article), after which the entire article 10, including the control body, may be disposed of. In other words, the control body may have a replaceable battery, so that the control body may be reused with multiple battery replacements and with many cartridges. This article 10 may be rechargeable and thus can be connected to any type of recharging technique, such as connection to a normal electrical outlet, connection to a car charger (i.e. cigarette lighter outlet), etc. connection, and may be combined with a connection to a computer, such as through a USB cable.

Control body 80 and cartridge 90 are specifically configured to engage each other to form an interconnected functional device. As shown in FIG. 3, the control body 80 includes a proximal coupling end 13, which includes a protrusion 82 of reduced diameter relative to the control body. The cartridge includes a distal coupling end 14 that engages a proximal engagement end of control body 80 to render smoking article 10 in a functional, ready-for-use configuration. In FIG. 3, control body protrusion 82 is provided with threads, thereby screwing cartridge 90 to control body 80 via corresponding threads (not visible in FIG. 3) on the distal coupling end of the cartridge. becomes possible. Accordingly, the distal coupling end of the cartridge 90 may include an open cavity for receiving the control body projection 82. Although threaded engagement is illustrated in FIG. 3, it is understood that additional means of engagement are included, such as press-fit engagement, magnetic engagement, and the like.

The arrangement of microheaters within the article may vary. In certain embodiments, one or more microheaters may be coupled to a substrate, which may be permanently incorporated into the smoking article or removed from the smoking article. Examples of such embodiments are shown in FIGS. 4 and 5. Referring first to FIG. 4, a substrate 600 is shown with a plurality of microheaters 50 mounted thereon. The microheater may be characterized as attached to the surface of the substrate, embedded within the substrate, or housed within the substrate (e.g., in a well as described elsewhere below). or in other depressions formed in the substrate). The substrate may be formed from any material suitable for use in smoking articles and preferably includes an electrically insulating material. The substrate material includes, but is not limited to, polymeric materials, particularly high temperature polymers, paper, cardboard, ceramics, and the like. Although five microheaters are shown in the illustrated embodiment, more or fewer microheaters may be utilized on a single substrate given the relatively small size of the microheaters. That is understood. Additionally, multiple substrates may be used, each substrate having one or more microheaters thereon. Although not explicitly shown, it is understood that the substrate may include any electrical wiring useful to form the electrical connections necessary for the microheater to be powered from a power source. Ru. Similarly, the substrate may include electrical contacts useful for forming electrical connections with plugs or other electrical components of the article. For example, each individual microheater may be wired to a common electrical contact on its substrate.

The aerosol precursor composition (or one or more components thereof) may be stored in a reservoir present in or on the substrate 600. For example, the perimeter of the substrate may include one or more containers, porous materials, etc. (useful for storing one or more components of the aerosol precursor therein), and one The above transport elements may be present to transport the aerosol precursor composition from the reservoir to the microheater. The microheater, reservoir) and transport element can be characterized as self-contained on a single substrate or on the same substrate. In other embodiments, no transport element may be present.

More specifically, FIG. 5 depicts one embodiment of a closed device when viewed as a cross-sectional view of the substrate at line AA in FIG. In this embodiment, microheater 50 is recessed a distance into substrate 600. Accordingly, the substrate may be described as comprising one or more heater wells 610. Individual microheaters may then be placed into heater wells and all or a portion of the remaining well volume may be filled with aerosol precursor composition 700 (or components thereof). The depth of the well may vary depending on the volume of aerosol precursor material used. In such embodiments, the aerosol precursor composition may advantageously be provided in a form such that the aerosol precursor composition does not dislodge significantly from the heater well 610, such as a gel or foam. , or other solid or semisolid forms. This gel or (another form of aerosol precursor) may be coated onto the microheater. Accordingly, the microheater may be characterized as being operably disposed within a smoking article that is in substantial contact with the aerosol precursor composition. Such description is applicable to further arrangements of aerosol precursor compositions and microheaters as described elsewhere herein.

As shown in FIG. 5, the heater well with the microheater and in which the aerosol precursor material is placed is present only on one side of the substrate. In other embodiments, the wells may be present on both sides of the substrate. Additionally, other substrate configurations, such as three-sided (e.g., with a triangular cross section), four-sided (e.g., with a square, rectangular, trapezoidal or other similar cross-section), or multi-armed cross-section (e.g., with three arms , four arms, or more). Such a configuration may provide sufficient surface area to provide a relatively large number of microheaters on a single substrate. For example, in a substrate with a four-arm cross-section (eg, cross-shaped), up to eight surfaces are available for the placement of microheaters. In other embodiments, the substrate may be in the form of a cylinder, and the microheaters may be distributed circumferentially on one or both of the inner and outer surfaces of the cylindrical shaped substrate. good.

Providing a relatively large number of microheaters may be particularly beneficial when it is desired to separately heat two or more components of the aerosol precursor composition. Specifically, see FIG. 5, one heater well 610 may contain one component of the precursor composition (e.g., polyol), and another heater well may contain a different component, e.g., perfume or drug. May include. The device may therefore include a controller adapted to activate microheaters corresponding to different components of the aerosol precursor composition according to different algorithms. For example, different microheaters may heat to different temperatures, heat for different lengths of time, or heat in a particular order. Additionally, a particular microheater may be automatically activated by a control component in response to activation of that device (e.g., upon activation of a pressure sensor indicating inhalation at that device), and other The microheater may be controlled manually (eg, by a push button). For example, one or more microheaters may be adapted to heat a particular fragrance (e.g., menthol), and the user of the device may have manual controls to deliver only the fragrance on demand. may also be used. As can be seen from the foregoing, the utilization of multiple microheaters allows for greater customization of the heating profile of the device and of the aerosol composition delivered in individual puffs at the device.

Still further configurations of microheaters in or on the substrate may be encompassed by the present disclosure. For example, multiple microheaters may be combined with a substrate to provide a bank of heaters. As shown in the embodiment of FIG. 6, a bank of microheaters 50 may be provided in the substrate. In this embodiment, the substrate 600 comprises a first layer 603 and a second layer 605, and the microheater may be sandwiched between the two layers. One of the first layer and the second layer may include a porous material that can function as a reservoir for the aerosol precursor composition (or components thereof), and the precursor composition (or one component thereof) The above components) may be stored over substantially the entire area of the layer or may be deposited only in one or more specific areas corresponding to one or more microheaters. Thus, an individual microheater can be activated to aerosolize the entire aerosol precursor composition in an area proximate to this microheater. Alternatively, individual microheaters may be activated to aerosolize specific components of the aerosol precursor composition in areas near the microheater.

In further embodiments, a substrate comprising an aerosol precursor composition (or one or more components thereof) may be provided, and one or more microheaters may be provided integrally with the apparatus described herein. It's okay. More specifically, a microheater may be disposed internally to a smoking article as discussed herein, and a substrate containing an aerosol precursor composition may be disposed within the article. Often, the substrate is then brought into substantial contact with a bank of microheaters or a single microheater. This substrate is replaceable, if desired, so that the article containing the bank of microheaters can be replaced by simply discarding the depleted substrate and replacing it with a fresh substrate with the aerosol precursor composition thereon. It can be reused by inserting it into an article. One such embodiment is illustrated in FIG.

As can be seen in FIG. 7, an embodiment of an electronic smoking article 10 is illustrated, which is essentially a single continuous body 150 having a hinged door 101. As shown in FIG. In the open position, the door reveals an aerosolization cavity lined with a series of microheaters 50. In the illustrated embodiment, this microheater is provided on the inner surface of the hinged door 101 and on the inner surface of the article. For use of this article, a substrate 600 containing an aerosol precursor composition is placed within the aerosolization cavity of the article. A generally flat substrate is then placed within the cavity such that the top and bottom surfaces of the substrate 600 are each in substantial contact with the series of microheaters, and the swing door 101 is closed. After use of the article substantially depletes the substrate of the aerosol precursor composition, the swing door may be opened and the substrate may be removed and replaced with a new substrate comprising the aerosol precursor composition. . In other embodiments, the microheater may be placed only on the inside of the swing door or on the inside surface of the aerosolization cavity. The series of microheaters may be configured to heat the substrate according to any algorithm desired, as previously described herein.

In some embodiments, the microheaters may be characterized as being arranged in a continuous manner. Alternatively, the microheaters may be provided in one or more different spatial arrangements. This particular arrangement of microheaters may be predefined to heat particular locations of the substrate in a particular order and/or to heat two or more different parts of the substrate simultaneously at the same point in time. may be predefined. Accordingly, the combination of multiple microheaters in the disclosed device may be characterized as an array of heaters.

Although the substrate 600 in FIG. 7 is illustrated as a generally flat rectangle, other shapes are possible, such as, for example, a cylinder. In other embodiments, the substrate may be a substantially elongated member having a defined cross-section, e.g., square, round, triangular, etc., the dimensions of the substrate being such that the aerosolization within the article is As long as it is sized to fit within the cavity, it may vary as desired so that the substrate is in substantial contact with one or more microheaters. Additionally, the number of microheaters lining the aerosolization cavity may vary. Similarly, as the shape and dimensions of the substrate are varied, the shape and dimensions of the aerosolization cavities within the article may vary accordingly, with the aerosolization cavities having substantially the same shape and dimensions as the substrate. good. In yet other embodiments, a hinged door 101 may be placed along either of the articles 10, thereby facilitating access to the aerosolization cavity. For example, the mouth end 11 of the article is configured such that the entire mouth end of the article is hinged to allow access to the aerosolization cavity for placement and removal of the substrate 600. It may be a swinging door. For example, such a structure may limit direct access to the microheater by the user.

In certain embodiments, the reservoir used to store the aerosol precursor composition can be a container (e.g., an airbag), and the article is capable of collecting a defined amount of the aerosol precursor composition from the container. can be adapted to measure. Mechanical components (eg, plungers and drive mechanisms, eg, springs) may be provided and may be electrically controlled by microheaters or similar components of the article. Micropump devices may in particular be used. Associated components may also provide an indication of the fluid fill status of the reservoir. Similarly, passive microfluidic devices may be used for the transfer of the aerosol precursor composition or one or more components thereof to the microheater. Such devices are particularly useful. The reason for this is that they do not necessarily require a separate power source and the control exerted by this device is based at least in part on the energy extracted from the liquid being transferred, or on surface tension, selective hydrophobicity/ This is because it can be based on surface effects such as hydrophilicity control. Examples of passive microfluidic devices are, for example, Springer Handbook of Nanotechnology, edited by Bharat Bhushan, Section 19.3, Smart Passive Microfluidic Device. ces ), November 29, 2006, pages 532-540, the disclosure of which is incorporated herein by reference in its entirety.

A reservoir containing an aerosol precursor composition may be in fluid communication with a microheater as discussed herein via one or more additional components. For example, the container may be contacted with a dispenser that facilitates the transfer of the liquid aerosol precursor composition out of the container and onto the microheater. The dispenser may be connected to the container via a suitable passageway, such as suitably dimensioned tubing or other transport element. Optionally, one or more valves may be configured such that the opening of the valve is outside or through a passageway in the reservoir (e.g., via electronic control by a microcontroller or similar component of the article) or in the dispenser. Provision may be made in that it may allow passage of the liquid aerosol precursor composition out and over the microheater. Such valve mechanisms may be present in addition to or in place of other mechanical components that actively displace the aerosol precursor composition from the container.

This dispenser can dispense the aerosol precursor composition onto the microheater (which may be on a separate substrate). In some embodiments, the dispenser may be integral with the microheater substrate or otherwise attached to the microheater substrate, and the dispenser may be integral with the microheater substrate or otherwise attached to the microheater substrate for its aerosolization and Various components may be provided to maintain the aerosol precursor composition near the microheater for release of the aerosol precursor composition.

This microheater may also be provided as part of a laminated substrate that can effectively be characterized as a spray device. For example, FIG. 8 illustrates an atomizer 800 that is a laminated structure forming an open cavity that laminates the microheater discussed herein. This microheater can therefore be characterized as being integral with the nebulizer. Specifically, the nebulizer 800 includes a support layer 510 with a conductive layer 520 thereon. A protective layer 540 is shown laminated with a conductive layer. Above the protective layer is the atomization chamber 810, which is an open space defined by the atomization chamber wall 820, the chamber cover 830, and the microheater (in particular the protective layer of the microheater). Although the chamber cover and protective layer are shown as partially transparent for ease of illustration, opaque or translucent materials may be used as well. A plurality of openings 840 are provided in the nebulization chamber wall to allow passage of vaporized aerosol precursor material out of the nebulizer. Preferably, the aperture is sized to allow vapor to pass through it, but not to allow liquid aerosol precursor composition to pass through it. A liquid passageway 850 connects the nebulizer to the reservoir, and the liquid passageway opens into a nebulization chamber to allow liquid precursor material to enter the chamber for evaporation. The liquid passageway may be tubing having a diameter of about 250 μm to about 1,000 μm, about 300 μm to about 750 μm, or about 400 μm to about 600 μm. As discussed herein, passage of liquid may occur via active or passive means. If passive means are used, the liquid passes freely into the chamber and waits for the vapor there, but does not exit through the opening 840. When the heater is activated, liquid is evaporated and exits the chamber through the opening, and the chamber is backfilled by the ingress of additional liquid precursor material. The atomization chamber is preferably sized such that substantially all of the liquid present in the chamber is completely evaporated in one go for removal therefrom. Optionally, means may be provided to prevent the passage of the vapor formed from the atomization chamber to the liquid passage. For example, a ball valve (not shown) may be provided at the opening of the liquid passage to the atomization chamber. The layers of the atomizer may be attached together like a eutectic metal bond.

Terminals 530 extending from the conductive layer 520 electrically connect the microheater (particularly the conductive material) with further electrical components of the article. The chamber walls and chamber cover may be formed from any suitable material that is heat resistant and chemically non-reactive with the aerosol precursor composition. For example, the chamber walls may be formed from silicon and the chamber cover may be formed from glass, but other materials discussed herein, for example, for use as a support layer and/or a protective layer, may be formed from glass. The materials may be used to independently form the chamber walls and chamber cover.

Although the structures discussed above may be particularly advantageous, they are not required; rather, the components described above may be combined in various ways. For example, the atomizer may be formed such that a microheater is thermally coupled to a atomization chamber formed from one or more walls. The chamber may be adapted to receive a predetermined amount of the aerosol precursor composition, such as through an opening in the chamber wall. The wall defining this chamber (including the cover, as specified) preferably has one or more openings adapted for the exit of vapor or aerosol from the chamber and for the inlet of air into the chamber. Be prepared. In certain embodiments, an opening adapted for vapor or aerosol outlet may also be used for air entry into the chamber.

The exemplary embodiment illustrated in FIG. 9 shows a sprayer 800 that includes a support layer 510, a spray chamber wall 820, and a spray chamber cover 830. The spray chamber, conductive layer, and protective layer are not visible in this view. In this embodiment, cover 830 includes a plurality of cover apertures 845, the chamber wall of which is continuous along the circumferential length of the atomizer. A liquid passageway 850 connects the atomizer to the reservoir and opens into the atomization chamber to allow liquid precursor material to pass to the chamber for evaporation. In this embodiment, the cover may be formed from a metal mesh and the cover openings allow the vaporized aerosol precursor composition to pass therethrough, but not the liquid aerosol precursor composition. The size is set as follows. Alternatively, the cover may be formed from other suitable materials, such as ceramics, high temperature polymers, silicone, glass, etc. The atomizer cover and the atomizer chamber wall may advantageously be formed as a unitary structure, such as by the use of suitable photolithographic techniques. Specifically, the cover may be bonded to a blank of material used for the atomization chamber walls, and etching may be used to remove the material needed to form the walls, leaving a chamber with the desired dimensions. . The chamber wall may then be bonded to a cover laminated to the support layer or a conductive layer on the support layer.

Due to the size of the microheater itself, the atomizer may also be relatively small. For example, the atomizer may have an overall length of about 2 mm to about 12 mm, about 3 mm to about 10 mm, or about 4 mm to about 8 mm, and an overall width of about 1 mm to about 7 mm, about 1.5 mm to about 6 mm, or about 2 mm to about 5 mm. may have. The nebulization chamber may have a volume of about 0.2 ml to about 1 ml, about 0.3 ml to about 0.9 ml, or about 0.4 ml to about 0.8 ml. One or more nebulizers may be included in the article, and the nebulizers may contain one or more reservoirs, which may contain the entire aerosol precursor composition or specific components of the aerosol precursor composition. and may be in liquid contact. The article comprises an aerosol precursor composition comprising a plurality of individual components, a plurality of reservoirs separately comprising the individual components of the aerosol precursor composition, and a predetermined amount of individual aerosol precursor compositions from the reservoir. and a plurality of atomizers or chambers adapted to receive the components of the invention.

In particular, the atomizer described above may be incorporated into a cartridge of a smoking article as described herein. For example, the nebulizer may be connected via a liquid passageway (eg, stainless steel tubing) to a reservoir such as a walled container. The reservoir may maintain a positive pressure therein for the aerosol precursor composition such that the liquid aerosol precursor composition continuously fills the chamber of the nebulizer after evaporation during use. In one embodiment, the reservoir may include a plunger biased, such as by a spring, to maintain a positive pressure on the liquid aerosol precursor composition in the reservoir. If desired, attached to the plunger may be an indicator that moves with the plunger. Accordingly, the smoking article may include a window in the body through which the indicator is visible. As the liquid aerosol precursor composition is depleted, the plunger moves in a defined direction. Therefore, the indicators also move in the same direction. The window may be arranged such that the indicator moves through the window and an indication of the filling status of the liquid aerosol precursor composition may be provided. For example, a color code may be utilized to indicate fill status with one or more different colors appearing in the window as the liquid is depleted. Similarly, a tapering indicator may be used to indicate fill status with the indicator moving from no tapering to fully tapering as the liquid is depleted. In other embodiments, a digital screen may be provided instead of a window, and the mechanical movement of the plunger may be electrically converted into a suitable signal to indicate the filling status on the digital screen. Similarly, a series of LEDs may be used to indicate fill status.

In addition to the above, it should be noted that different reservoirs may be utilized for the various embodiments described above. For example, the reservoir may be a container, such as a bottle, in which the aerosol precursor composition is stored. The container may be substantially impermeable to the aerosol precursor so that the material cannot escape through the walls of the container. In such embodiments, an opening may be provided for passage of the aerosol precursor composition therethrough. The term "bottle" is meant to generally encompass any container that has walls and at least one opening. A tube or other conduit may be used for passage of the aerosol precursor composition outside the bottle and through the tube or other conduit. Such passage may also occur through capillary action. Alternatively, passive flow of liquid from the bottle may be used to allow flow of the aerosol precursor composition when the smoking article is in use, and of the aerosol precursor composition when the smoking article is not in use. It may be controlled with a suitable valve mechanism that can be opened to prevent flow. Active flow mechanisms incorporating micro-pump devices are also contemplated for use in accordance with the present invention. Such containers may be formed from any suitable material that is not substantially reactive with any of the components of the aerosol precursor composition, such as glass, metal, low porosity or non-porous ceramics, plastics, etc. Good too.

In some embodiments, the reservoir is used to retain the aerosol precursor composition (e.g., through absorption, adsorption, etc.) and to allow the precursor composition to escape for transport to the microheater. It may also be a suitable woven or non-woven fabric or another mass of fibers. Such reservoir layers may be formed from natural fibers, synthetic fibers, or combinations thereof. Non-limiting examples of useful materials include cotton, cellulose, polyester, polyamide, polylactic acid, combinations thereof, and the like. Similarly, the reservoir may be formed from ceramic, other porous materials, sintered materials, and the like. Smoking articles according to the invention may include one reservoir or multiple reservoirs (eg, two reservoirs, three reservoirs, four reservoirs, or more). As discussed herein, the reservoir may be essentially a substrate with one or more microheaters. Such a substrate may be formed from porous materials such as those described above.

In certain embodiments, a wick may be used to transport one or more aerosol precursor compositions from a reservoir of a smoking article to a microheater. Thus, the wick for use in accordance with the present invention may be any material that provides sufficient wicking action to transport one or more components of the aerosol precursor composition to the microheater. Non-limiting examples include natural or synthetic fibers such as cotton, cellulose, polyesters, polyamides, polylactic acids, glass fibers, combinations thereof, and the like. Other exemplary materials that may be used for the wick include metal ceramics, and carbonized filaments (eg, materials formed from carbonaceous materials that have undergone calcination to drive off the non-carbon components of the material). The wick may further be coated with a substance that alters the capillarity of the fibers, and the fibers used to form the wick may have a particular cross-sectional shape and are grooved to alter the capillary action of the fibers. may be added. The fibers used to form the wick may be provided individually, in bundles, as woven fabrics (including meshes and braids), or as non-woven fabrics. The porosity of the wick material may also be controlled to modify the capillarity of the wick, including controlling the average pore size and total porosity, and controlling the wick geometry (or fiber geometry). control, and control of surface features. Different wicks may also have different lengths. The term "wick" is also intended to encompass capillaries, and any combination of elements that provides the desired capillarity may be used.

Aerosol precursor compositions utilized in smoking articles may be formed from a first component and at least a second individual component. Thus, the aerosol precursor composition may be formed from multiple components, such as two individual components, three individual components, four individual components, five individual components, and the like. In some embodiments, individual components of the aerosol precursor composition may be separately transported to separate microheaters. Separate transport may in this regard be applied to each individual component of the aerosol precursor composition or to any combination of individual components. In some embodiments, two or more components of an aerosol precursor composition may be stored in the same reservoir and may also be transported separately to separate microheaters or to the same microheater. May be transported. Using various combinations of one or more reservoirs, one or more transport elements, and one or more microheaters, all of different designs and made of different materials, the aerosol precursor Controlled rate transport and heating of the components of the composition may be achieved.

Advantageously, by utilizing separate transport of the individual components of the aerosol precursor composition to separate the heating elements, the individual components can be heated to different temperatures to provide a more consistent solution for the user to inhale. It may be possible to obtain a certain amount of aerosol. The aerosolization temperatures of the separate heaters are substantially the same, but in some embodiments, the aerosolization temperatures of the separate heaters are 2°C or higher, 5°C or higher, 10°C or higher, 20°C or higher, 30°C or more, or may differ by 50°C or more.

In addition to the foregoing, the control body and cartridge may be characterized in terms of overall length. For example, the control body may have a length of about 50 mm to about 110 mm, about 60 mm to about 100 mm, or about 65 mm to about 95 mm. The cartridge may have a length of about 20 mm to about 60 mm, about 25 mm to about 55 mm, or about 30 mm to about 50 mm. The overall length of the combined cartridge and control body (or the overall length of a smoking article according to the invention formed from a single, single shell) is approximately equal to or equal to the length of a typical cigarette. (eg, about 70 mm to about 130 mm, about 80 mm to about 125 mm, or about 90 mm to about 120 mm).

Although the cartridge and control body may be provided together as a complete smoking article, or drug delivery article in general, the components thereof may also be provided separately. For example, the invention may also include disposable units for use with reusable smoking articles or reusable drug delivery articles.

In certain embodiments, a disposable unit or cartridge according to the present invention may be substantially identical to a cartridge as described above with respect to the accompanying drawings. Thus, the disposable cartridge has a distal end configured to engage a reusable smoking article, or a drug delivery article, and a vapor and any additional inhalable substance formed to the consumer. The cartridge shell may have a substantially annular shape with opposing mouth ends configured to permit passage of the cartridge shell. This cartridge shell may define an internal cartridge space that includes additional cartridge components, particularly one or more microheaters.

Although the various figures described herein show the control body and cartridge in a working relationship, it is understood that the control body and cartridge may exist as separate devices. Accordingly, it should be understood that any discussion described elsewhere herein with respect to the combined components applies to the control body and cartridge as individual and separate components.

In another aspect, the invention may relate to kits that provide various components as described herein. For example, a kit may include a control body with one or more cartridges. The kit may further include a control body that includes one or more charging components. The kit may further include a control body that includes one or more batteries. The kit may further include a control body that includes one or more cartridges, one or more charging components, and/or one or more batteries. In further embodiments, the kit may include multiple cartridges. The kit may further include a plurality of cartridges and one or more batteries and/or one or more charging components. Kits of the invention may further include a case (or other packaging, carrying, or storage component) that accommodates one or more of the additional kit components. The case may be a reusable rigid or flexible container. Additionally, the case may simply be a box or other packaging structure.

In a further embodiment, the present disclosure further encompasses a method of forming an aerosol in a smoking article. Specifically, the method may include activating an electrical current from a power source within the smoking article to a microheater of the smoking article, thereby causing the microheater to heat the aerosol precursor composition.

In some embodiments, smoking articles utilized in this method may include multiple microheaters. Two or more microheaters may be heated simultaneously. Still further, the aerosol precursor composition may include two or more individual components, and the individual components of the aerosol precursor composition may be heated separately by simultaneously heated microheaters. . More specifically, this simultaneously heated microheater may receive current from a power source under different conditions, so that this microheater is heated to different temperatures or heated for different times. be done. If desired, two or more microheaters may be heated in sequence (ie, in a defined array or pattern).

In further embodiments of the method, the aerosol precursor composition may be coated onto, adsorbed to, or absorbed into a carrier material (i.e., a substrate) and initiates an electrical current. The method may include inserting a carrier material into the smoking article. Similarly, the microheater may be attached to the substrate and, prior to activating the current, the method may include inserting the substrate into the smoking article. In certain embodiments, the aerosol precursor composition may be coated onto a microheater attached to a substrate. In other embodiments, the method includes initiating flow of the aerosol precursor composition from the reservoir into a chamber that is thermally coupled to the reservoir, thereby heating the aerosol precursor composition within the chamber. may be included.

Modifications and other embodiments of the invention will occur to those skilled in the art having the benefit of the foregoing description and the techniques illustrated in the associated drawings. It is therefore understood that this invention is not limited to the particular embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Should. Certain terms used herein are used in a generic and descriptive sense only and not for the purpose of limitation.

Claims (35)

A smoking article comprising a power source and a microheater electrically connected to the power source. 2. The smoking article of claim 1, wherein the microheater is a microelectromechanical systems (MEMS) based heater. The smoking article of claim 1, wherein the microheater is a thin film heater. 2. The smoking article of claim 1, wherein the microheater comprises a patterned conductive material. 5. The smoking article of claim 4, wherein the electrically conductive material is selected from the group consisting of elemental metals, metal alloys, silicon, ceramics, carbon, carbides, nitrides, and combinations thereof. 5. The smoking article of claim 4, wherein the microheater comprises a support layer and a conductive material patterned on the support layer. 7. The smoking article of claim 6, wherein the conductive material is a printed layer laminated to the support layer or the conductive material is an etched layer laminated to the support layer. . 5. The smoking article of claim 4, wherein the microheater comprises a protective layer laminated to the patterned conductive material. The smoking article of any one of claims 6-8, wherein the support layer or the protective layer is temperature stable in a temperature range of about 125°C to about 750°C. A smoking article according to any one of claims 6 to 8, wherein the support layer or protective layer comprises a silicon-based material. 2. The smoking article of claim 1, wherein the microheater comprises two or more layers. 2. The smoking article of claim 1, wherein the microheater comprises an electrically conductive material sandwiched between two membranes. The smoking article of claim 1, wherein the microheater has a length of about 3 mm or less and a width of about 3 mm or less. The smoking article of claim 1, wherein the microheater has a length of about 0.5 mm to about 3 mm and a width of about 0.5 mm to about 3 mm. The smoking article of claim 1, wherein the microheater is attached to a substrate. 16. The smoking article of claim 15, wherein the substrate is formed from an electrically insulating material. 2. The smoking article of claim 1, comprising a plurality of microheaters. The smoking article of claim 1 further comprising an aerosol precursor composition. 19. The smoking article of claim 18, wherein the aerosol precursor composition is in liquid or gel form at ambient conditions. 20. The smoking article of claim 19, wherein the aerosol precursor composition is in a reservoir such that the aerosol precursor composition is spaced from the microheater. 21. The smoking article of claim 20, wherein the article comprises a controller adapted to deliver a defined amount of the aerosol precursor composition to the microheater. 21. The smoking article of claim 20, wherein the microheater is thermally coupled to a chamber, the chamber being adapted to receive a predetermined amount of the aerosol precursor composition through an opening in the chamber. . 23. The smoking article of claim 22, wherein the chamber comprises an opening adapted for the exit of vapor from the chamber. 23. The smoking article of claim 22, wherein the chamber has a volume of about 0.2 ml to about 1 ml. said aerosol precursor composition is coated onto, adsorbed to, or absorbed into a carrier material, said carrier material being in substantial contact with said microheater; 19. The smoking article of claim 18, wherein the smoking article is disposed within the article. 2. The smoking article of claim 1, wherein the microheater is integral with an atomizer. 27. The smoking article of claim 26, wherein the atomizer comprises a chamber defined by a wall, a cover, and a protective layer laminated to the microheater. 28. The smoking article of claim 27, wherein one or both of the wall and the cover comprises a plurality of openings sized to permit passage of vapor but not liquid. A method of forming an aerosol in a smoking article, the method comprising: causing a current from a power source within the smoking article to flow through a microheater within the smoking article, whereby the microheater and an aerosol precursor are in contact with the microheater. A method comprising heating a composition. 30. The method of claim 29, wherein the smoking article comprises a plurality of microheaters. the aerosol precursor composition is coated onto, adsorbed to, or absorbed into a carrier material, and before the step of activating the electrical current, the method further comprises: 30. The method of claim 29, comprising inserting the carrier material within an article. further comprising initiating flow of the aerosol precursor composition from a reservoir to a chamber that is thermally coupled to the microheater, thereby heating the aerosol precursor composition within the chamber; 30. The method of claim 29. CLAIMS 1. A nebulizer suitable for use in an electronic smoking article, comprising a chamber formed from a chamber wall, a cover and a microheater. 34. The nebulizer of claim 33, wherein one or both of the chamber wall and the cover comprises a plurality of apertures. 35. The atomizer of claim 34, wherein one or more of the plurality of apertures are sized to allow passage of vapor but not liquid.

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