United States Patent [191
`Brooks et a1.
`
`1111 Patent Number:
`[45] Date of Patent:
`
`4,947,875
`Aug. 14, 1990
`
`[54] FLAVOR DELIVERY ARTICLES UTILIZING
`ELECTRICAL ENERGY
`
`[75] Inventors: Johnny L. Brooks; Donald L.
`Roberts, both of Winston-Salem;
`Jerry S. Simmons, Rural Hall, all of
`N‘C'
`[73] Ass‘gnee‘ R'.J' Reymld‘ T°h°°° mummy’
`wmsmn'salem' N-C-
`
`0:
`21 A 1_
`[
`1
`pp No 242383
`[22] Filed:
`Sep. 8, 1988
`
`,
`
`[51] Int. Cl.5 ....................... .. A24F 1/00; A24F 47/00
`[52] US. Cl. .................................. .. 131/330; 131/273;
`131/194; 131/195; l28/202.2l; l28/203.27;
`128/204.23; 128/204.24
`[58] Field of Search ............. .. 131/330, 273, 194, 195;
`128/202.21, 203.27, 204.23, 204.29
`References Cited
`
`[56]
`
`4,303,083 12/1981 Burruss, Jr. -
`4,523,589 6/1985 Krauser .
`4,564,748 1/1986 Gupton .
`4,580,583 4/1986 Green, Jr. .
`4,735,217 4/1988 Gerth et a1. .
`4,771,796 9/1988 Myer .
`FOREIGN PATENT DOCUMENTS
`186280 7/1986 European Pat. Off. .
`2653133 5/1978 Fed. Rep. of Germany .
`2704218 8/1978 Fed. Rep. of Germany .
`3300992 7/1984 Fed. Rep. of Germany .
`2128256 10/1972 France .
`48-8231 3/1973 Japan .
`wO86/02528 5/1986 PCT In“ App!’ _
`197946 4/1924 United Kingdom '
`
`Primary Examiner-—V. Millin
`
`ABSTRACT
`[57]
`Flavor delivery articles employ an electrical resistance
`heating element and an electrical power source to pro
`vide a ?avored aerosol. The articles advantageously
`comprise a disposable portion and a reusable controller.
`The disposable portion normally includes a ?avor sub
`stance and an air permeable resistance heating element
`.
`2
`.
`having a surface area greater than 1 m /g, WhlCh usu
`ally carries an aerosol forming substance. The reusable
`controller normally includes a puff-actuated current
`actuation means, a time-based current regulating means
`to control the temperature of the heating element, and a
`battery power supply‘
`
`136 Claims, 8 Drawing Sheets
`
`U‘S' PATENT DOCUMENTS
`1,771,366 7/1930 Wyss et al. .
`1,968,509 7/ 1934 Tiffany -
`2'057’353 10/1936 Wm?‘ Jr‘ '
`2,104,266 I/ 1938 McCormick .
`2 974 669 3/1961 Ems
`3:200:319 3/1965 G?ben _
`3,889,690 6/1975 Guamieri .
`3,918,464 11/1975 Kolodziej .
`1,
`gross ct 11- -
`4,164,230 8/1979 Pearlman .
`4,193,411 3/1980 Faris et al. .
`4,246,913 1/ 1981 Ogden et a1. .
`
`y
`
`9
`
`muss .
`
`44
`
`48 42 38 I6
`
`/IO
`
`46 49 54 4O 52 36
`
`58
`
`28
`
`32
`
`62
`
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`

`

`" us. Patent Aug.14,1990
`
`Sheet 1 of8
`
`I 4,947,875
`
`mm
`
`on $339. ow 2 8? we 3
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`on 0*
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`
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`

`US. Patent Aug. 14, 1990
`
`Sheet 2 of 8
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`4,947,875
`
`N .07..
`
`/
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`/
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`

`

`US. Patent Aug. 14,1990
`
`Sheet 3 of8
`
`4,947,875
`
`2(2
`
`O@
`
`6(8 74/66/12 1876/54/79 76
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`74
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`72
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`28
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`
`FIG.3
`
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`US. Patent Aug. 14,1990
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`Sheet 4 of 8
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`4,947,875
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`I4 74 48 42 I6 49 46
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`/
`
`28
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`
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`US. Patent Aug. 14, 1990
`
`Sheet 5 of8
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`4,947,875
`
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`U.s. Patent Aug.14,1990
`
`Sheet 6 on;
`
`4,947,875
`
`IIO
`
`2
`
`(O
`
`I24
`
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`

`US. Patent Aug. 14, 1990
`
`Sheet 7 of8
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`4,947,875
`
`IIO
`
`28
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`‘US. Patent Aug. 14,1990
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`’ Sheet 8 of 8
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`4,947,875
`
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`
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`
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`

`

`FLAVOR DELIVERY ARTICLES UTILIZING
`‘
`ELECTRICAL ENERGY
`
`5
`
`15
`
`BACKGROUND OF THE INVENTION
`The present invention relates to ?avor delivery arti
`cles which employ an electrical resistance heating ele
`ment and an electrical power source to produce a ?a
`vored aerosol.
`Over the years, there have been proposed numerous
`smoking products, ?avor generators and medicinal in
`halers which utilize electrical energy to vaporize or
`heat a volatile material for delivery to the mouth of the
`user.
`U.S. Pat. No. 2,057,353 to Whittemore, Jr. proposed a
`vaporizing unit. In particular, a wick reportedly carried
`liquid medicament by capillary action to a point where
`the liquid was vaporized by an electrical resistance
`heating element.
`US Pat. No. 2,104,266 to McCormick proposed an
`article having a pipe bowl or cigarette holder which
`included a resistance coil (i) wound on an insulating and
`heat resisting material, and (ii) contained in an insulated
`chamber. Prior to use of the article, the pipe bowl was
`25
`?lled with tobacco or the holder was fit with a ciga
`rette. Current then was passed through the resistance
`coil. Heat produced by the resistance coil was transmit
`ted to the tobacco in the bowl or holder, resulting in the
`volatilization of various ingredients from the tobacco.
`A thermostatic switch was employed to maintain a
`predetermined temperature range to which the tobacco
`was heated.
`U.S. Pat. No. 3,200,819 to Gilbert proposed a smoke
`less, non-tobacco cigarette having a ?avor cartridge,
`such as a porous substrate impregnated with mentho
`lated water. The article included a battery for powering
`a tube or bulb which was illuminated before assembly.
`The bulb was placed in a tubular liner, which was in
`turn located within a tube of plastic having the size,
`color and form of a cigarette. In use, the illuminated
`bulb reportedly heated the ?avored air drawn through
`passages formed between the bulb and the tubular liner.
`As such, warm, moist, ?avored air was delivered to the
`user.
`French Patent Publication No. 2,128,256 to Ribot et
`al proposed an article for delivering denicotinized
`smoke. The proposed article included a sealed ampule
`which contained pressurized denicotinized smoke. An
`electric resistor was immersed in the smoke. In use, the
`terminals of the resistor were pushed into contact with
`a microbattery causing the resistor to generate heat and
`heat the smoke within the ampule. Draw by the user
`reportedly caused warm smoke to exit a valve near the
`mouthend of the article.
`Japanese Patent Publication No. 8231/73 to Takeda
`proposed a cigar-shaped inhaler which included a bat
`tery powered Nichrome wire to heat air that, in turn,
`evaporated an essence from an essence container. The
`Nichrome wire was energized by either a manually
`actuated or a draw actuated “on-oft” switch.
`West German Patent application No. 2,653,133 to
`Kovacs proposed a smoking simulator having an inter
`nal battery which could accelerate or control the vapor
`ization or emission of aromatic substances for delivery
`to the user. In supplemental West German Patent appli
`cation No. 2,704,218, Kovacs described the use of a
`
`20
`
`35
`
`45
`
`55
`
`65
`
`1
`
`4,947,875
`
`2
`vacuum or draw-actuated switch to switch “on” the
`battery operated heating coil.
`A draw actuated, pressure transducer switch was
`described in U.S. Pat. No. 4,246,913 to Ogden et al, as
`part of a smoke aversion therapy article which deliv
`ered a small electrical shock to a smoker whenever the
`smoker drew on a cigarette.
`U.S. Pat. No. 4,141,369 to Burruss proposed an article
`similar to the previously discussed McCormick articles.
`Burruss proposed a container which was electrically
`heated to a temperature sufficient to volatilize desired
`components from smoking material inserted therein.
`Heated air passing through the container during draw
`reportedly carried volatilized materials to the mouth of
`the user.
`U.S. Pat. No. 4,303,083 to Burruss proposed a pipe
`having an electrical resistance heating element, a manu
`ally operated “on-off” power switch, and an opening
`above the resistance element for the addition of volatile
`compound. During use, the volatile compound was
`applied, using a squeeze tube or eye dropper, to a heated
`surface within the pipe, apparently on a puff-by-puff
`basis. The volatile compounds reportedly were vapor
`ized, mixed with air drawn into the pipe, and inhaled by
`the user.
`PCT Publication No. WO 86/02528 to Nilsson et al
`proposed an article similar to that described by McCor
`mick. Nilsson et al proposed an article for releasing
`volatiles from a tobacco material which had been
`treated with an aqueous solution of sodium carbonate.
`The article resembled a cigarette holder and reportedly
`included a battery operated heating coil to heat an un
`tipped cigarette inserted therein. A switch was acti
`vated to supply current to the heating coil. A tempera
`ture sensor reportedly disconnected and reconnected
`the battery in order to maintain the temperature gener
`ated by the device in a narrow temperature range. Air
`drawn through the device reportedly was subjected to
`elevated temperatures below the combustion tempera
`ture of tobacco and reportedly liberated tobacco ?avors
`from the treated tobacco contained therein.
`U.S. Pat. No. 4,735,217 to Gerth et al proposed a
`“cigarette-shaped” medicament dosing article having a
`pellet of vaporizable medicament and a Nichrome resis
`tance heating element connected in series with a battery
`power source and a draw actuated switch. In their only
`working example, the Nichrome heating element alleg
`edly achieved a temperature in the range of 190° F. to
`220° F. (90° C. to 105° C.) within a two second puff,
`which apparently was sufficient to volatilize menthol
`from a menthol pellet. At Column 8, lines 43-63, Gerth
`et al. went on to speculate that their article could be
`used to vaporize nicotine from a nicotine-containing
`pellet and that they believed it feasible to coat the heat
`ing element with a nicotine-containing compound in
`lieu of using a vaporizable pellet.
`However, it is believed that it would not be possible
`to coat a Nichrome heating element, of the type de
`scribed by Gerth et al, with enough vaporizable liquid
`material to deliver suf?cient volatile material to the
`user, over a 6 to 10 puff life. It also is believed that the
`article of Gerth et a1 would not be able to provide
`enough electrical energy to (i) vaporize volatile mate
`rial until near the end of a typical two second puff, or
`(ii) provide a high enough temperature (e.g., 150° C. to
`350° C.) to vaporize many volatile materials within a
`two second puff, including many desirable aerosol
`forming 'substances and many volatile ?avor compo
`
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`

`0
`
`20
`
`25
`
`35
`
`4,947,875
`3
`4.
`tional area of the disposable portion. In other preferred
`nents. In addition, even with only a single AA battery,
`the article described by Gerth et al. is more than 3 times
`embodiments, the resistance heating element is located
`the diameter and many times heavier than a typical
`adjacent an end of the disposable portion, and/or at
`cigarette and is provided with a relatively imprecise
`least substantially ?llS the cross-sectional area of the
`draw actuated control switch and with no means of
`disposable portion or the air passageway therethrough.
`regulating the current or heat during the puff.
`A reusable controller can be used with the disposable
`Despite many years of interest and effort, none of the
`portions of the invention. This reusable controller nor
`foregoing articles employing electrical energy has ever
`mally includes a current actuation means, a separate
`realized any signi?cant commercial success, and it is
`current regulating means to control the temperature of
`believed that none has ever been widely marketed.
`the heating element, and a battery power supply. Alter
`Moreover, it is believed that none of the foregoing
`natively, the electrical power supply can be provided
`electrical energy articles is capable of effectively pro
`separately from the current actuation and current regu
`viding acceptable ?avor delivery to the user., especially
`lating means; e.g., as a separate battery pack or as nor
`a 6 to 10 puff, or greater, product life.
`mal household current stepped down by an appropriate
`Thus, it would be desirable to provide a ?avor deliv
`transformer. The reusable controller can be in the form
`ery article which utilizes electrical energy and which is
`of a pipe, a reusable mouthpiece, a hand-held unit or
`capable of delivering acceptable quantities of ?avored
`other portable form into which the disposable portion
`aerosol over at least 6 to 10 puffs.
`can be inserted. The use of such a reusable article with
`the disposable portions of the invention is particularly
`advantageous in that it permits the use of (i) relatively
`large power sources, capable of generating 10 to 40
`watts of power or more, and (ii) accurate and sophisti
`cated current actuation and current regulating means
`that normally would be too costly to incorporate into a
`single use, disposable article.
`Preferably, the current actuation means is puff actu
`ated, so that current ?ows through the resistance heat
`ing element to produce ?avored aerosol only during
`draw by the user.
`To use the articles of the invention, the user simply
`inserts the disposable portion containing the ?avor sub
`stance into the controller, to electrically connect the
`heating element to a circuit including the current actua
`tion and current regulating means and to the battery.
`When the user draws on the mouthend of the article, the
`preferred current actuation and current regulating
`means permit unrestricted or uninterrupted ?ow cur
`rent through the resistance heating element to generate
`heat rapidly. This heating volatilizes the aerosol form
`ing substances and/or ?avors, which in turn form an
`aerosol and pass through the article and into the mouth
`of the user. At the same time, the current regulating
`means (i) regulates current ?ow through the heating
`element to control heating of the resistance element and
`the temperature experienced thereby, and (ii) prevents
`overheating and degradation of the aerosol former.
`When the user stops drawing on the article, the current
`actuation means prevents further current ?ow through
`the heating element and disables the current regulating
`means. This process continues, puff after puff, until the
`user decides to stop drawing on the article. At that
`point, the disposable portion can be removed and dis
`carded, and a new one inserted in its place.
`In another aspect of the invention, the current actua
`tion means, the current regulating means, and/or the
`electrical power source may be incorporated into the
`portion of the article containing the electrical resistance
`heating element, so that the reusable controller may be
`reduced in size or even eliminated.
`Preferred ?avor delivery articles of the invention are
`capable of delivering an average of at least 0.5 mg, more
`preferably at least 0.8 mg, of aerosol and/or ?avor
`substance per puff, measured as wet total particulate
`matter (WTPM), under conditions of 2 second, 35 ml
`puffs, taken once every 60 seconds. Preferred articles of
`the invention can deliver such material, preferably in
`visible form, for a plurality of puffs, preferably at least
`
`SUMMARY OF THE INVENTION
`The present invention relates to ?avor delivery arti
`cles which employ an electrical resistance heating ele
`ment and an electrical power source to provide a ?a
`vored aerosol. Preferred articles can produce aerosol
`almost immediately upon commencement of a puff, as
`well as provide the controlled production of aerosol
`throughout the puff and over a 6 to 10 puff product life.
`In one aspect of the invention, the ?avor delivery
`article includes a disposable portion (e.g., a cartridge)
`which utilizes an air permeable high surface area electri
`cal resistance heating element that normally carries
`aerosol forming and/or ?avor substances prior to use.
`This resistance heating element typically is a porous
`material having a surface area greater than 1 m2/ g, as
`determined using the Brunaver, Emmett and Teller
`(BET) method described in J. Am. Chem. Soc, Vol. 60,
`p. 309 (1938); and Adsorption Surface Area and Porosity,
`Gregg et a1, Academic Press, NY (1967). Preferably,
`the heating element is a ?brous carbon material, most
`preferably having a surface area greater than about
`40
`1,000 mZ/g. (In contrast, the surface area of the Ni
`chrome metal resistance element of Gerth et al is be
`lieved to be about 0.01 mZ/g.) Preferably, such porous
`heating elements are impregnated with liquid aerosol
`forming substances, such as glycerin, and with a flavor
`such as a coffee extract or menthol. Such heating ele
`ments are particularly advantageous in that they are
`capable of holding and efficiently releasing relatively
`large quantities of liquid aerosol forming substances and
`?avor materials. For example, such heating elements
`can carry enough aerosol forming substances to provide
`aerosol for 6 to 10 puffs, or more.
`Another important aspect of the invention relates to
`the various configurations of the disposable portions
`described herein. For example, in certain preferred
`embodiments, the disposable portion advantageously is
`provided with an electrical connection means at one
`end thereof. This electrical connection means includes
`means for connecting the resistance element to a battery
`or other external power source, and preferably includes
`an air passageway used in conjunction with the pre
`ferred puff actuated current actuation means. In other
`preferred embodiments, the disposable portion is
`adapted for connection to the external power source via
`connectors located on the reusable controller. In certain
`preferred embodiments, the resistance heating element
`-is located centrally in the disposable portion and/or
`does not occupy a signi?cant portion of the cross-sec
`
`45
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`65
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`

`BRIEF DESCRIPTION OF TI-HE DRAWINGS
`FIG. 1 is a longitudinal, partial sectional view of an
`article of this invention;
`FIG. 1A is a sectional view of a portion of the em
`bodiment shown in FIG. 1 taken along lines 1-1;
`FIG. 2 is a longitudinal, partial sectional view of an
`article of this invention;
`FIG. 3 is a perspective of an article of this invention
`including an exposed inner view of the reusable portion
`thereof;
`FIGS. 4, 5, and 6 are longitudinal, partial sectional
`views of preferred articles of this invention showing the
`disposable portions and cut-away views of the control
`lers;
`FIGS. 7 and 8 are longitudinal sectional views of
`additional articles of the invention;
`FIGS. 9 and 10 are representative schematic dia
`grams of time-based control circuits and related wiring
`for preferred controllers useful in this invention; and
`FIG. 11 depicts the temperature, average current
`voltage pro?les experienced by a resistance heating
`element during heating controlled by the preferred
`current regulating means.
`
`15
`
`20
`
`25
`
`30
`
`4,947,875
`5
`6
`about 6 puffs, more preferably at least about 10 puffs,
`permit relatively precise control of the temperature
`under such conditions.
`range experienced by the aerosol forming substance,
`As used herein, and only for the purposes of this
`especially when the preferred time based current con
`application, “aerosol” is de?ned to include vapors,
`trol means described herein is employed.
`gases, particles, and the like, both visible and invisible,
`Preferred resistance heating elements include carbon
`generated by action of heat from the resistance heating
`?lament yarns available from American Kynol, Inc.,
`element upon aerosol forming substances and/or ?avor
`New York, NY, as Catalog Nos. CFY-0204-l, CFY
`substances located on the resistance element or else
`0204-2, and CFY-0204-3. Such yarns reportedly have
`where in the article.
`surface areas of about 1,500 mZ/g and resistivities of
`The articles of the present invention are described in
`about 10 to about 30 milliohm-cm. See, Kirk-Othmer:
`greater detail in the accompanying drawings and in the
`Encyl. Chem. Tech, Vol. 16, 3rd Ed., pp 135-136 (1981).
`detailed description of the invention which follows.
`Representative lengths of such yarns range from about
`15 to about 50 mm. Other preferred heating elements
`include carbon felts and activated carbon felts available
`from American Kynol, Inc., as Catalog Nos. CN
`157(HC), CN-210(HC), ACN-2l l-lO, ACN-2l0‘l0, and
`ACN-l57-l0. Such felts typically have surface areas of
`about 1,500 mz/ g and resistivities of about 5 to about 30
`milliohm-cm. Such felts can be used in the form of
`circular discs having diameters of about 4 to 8 mm, as
`described in greater detail hereinafter with reference to
`FIGS. 4-6. Other suitable heating elements include
`porous metal wires or ?lms; carbon yarns, cloths, ?bers,
`discs or strips; graphite cylinders, fabrics or paints;
`microporous high temperature polymers having moder
`ate resistivities; porous substrates in intimate contact
`with resistance heating components; and the like.
`Preferably, the heating element 18 is impregnated
`with or otherwise carries one or more aerosol forming
`substances in order that the aerosol forming substances
`are in a heat exchange relationship with the electrical
`heating element. The aerosol forming substances used in
`this invention are capable of forming aerosol during
`periods when the heating element generates heat. Such
`substances preferably are composed of carbon, hydro
`35
`I gen and oxygen, although other material such as water
`can be employed. The aerosol forming substances can
`have a solid, semi-solid, or liquid form. Examples of
`suitable aerosol forming substances include water; etha
`nol; polyhydric alcohols such as glycerin, propylene
`glycol and triethylene glycol; aliphatic esters of mono
`,di-, or poly-carboxylic acids such as methyl stearate,
`dimethyl dodecandioate, dimethyl tetradecandioate; a
`?avor such as menthol, chocolate, coffee, fruit or arti
`?cial fruit; and the like, as well as mixtures thereof.
`While the loading of the aerosol forming substance
`can vary from substance to substance and from heating
`element to heating element, the amount of liquid aerosol
`forming substance used typically will be greater than
`about 15 mg and preferably ranges from about 25 mg to
`about 50 mg.
`The ?avor substances used in this invention are those
`which are capable of being delivered to the user in
`aerosol form. Such flavors include menthol, pepper
`mint, spearmint, cinnamon, vanilla, licorice, ginger,
`mouth fresheners, chocolate, coffee and coffee ?avors,
`liqueurs, root beer, spice, nut, pepper, pizza, bacon,
`sausage, cereal, popcorn, cookie, strawberry, citrus,
`raspberry, cherry, tooty fruity, and the like.
`Such ?avor substances can be used as aerosol forming
`substances, and can be carried by the resistance heating
`element. Such flavor substances also can be placed be
`tween the resistance heating element and the mouthend
`of the cartridge, such as in mouthend ?lter 22 or in a
`separate ?avor chamber or cartridge located between
`the resistance heating element and the ?lter. In such
`instances, the ?avor substance can either form an aero
`sol or be eluted by the aerosol forming material. As
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENTS
`Referring to FIG. 1, ?avor delivery article 10 in
`cludes a disposable cartridge 12 and a reusable, hand
`held controller 14. The disposable cartridge 12 includes
`electrical connection plug 16, resistance heating ele
`ment 18 carrying an aerosol forming substance, mouth
`end ?lter 22, and a resilient overwrap 24. The preferred
`4-5
`controller 14 includes a case 26, a puff actuated current
`actuation mechanism 28 having the form of a pressure
`sensitive switch, a time-based current control circuit 30,
`and a chamber 32 into which battery power supply 34
`(shown as batteries 34A and 34B) is inserted.
`The resistance heating element 18 employed in car
`tridge 12 preferably is a ?brous material having a high
`surface area and an adsorbant, porous, wettable charac
`ter, in order to carry a suitable amount of aerosol form
`ing substance for effective aerosol formation. Suitable
`heating elements preferably have surface areas above
`about 50 m2/ g, more preferably above about 250 m2/ g,
`and most preferably above about 1,000 mz/ g.
`Preferred heating elements normally have low mass,
`low density, and moderate resistivity, and are thermally
`stable at the temperatures experienced during use. Such
`heating elements heat and cool rapidly, and thus pro
`vide for the efficient use of energy. Rapid heating of the
`element also provides almost immediate volatilization
`of the aerosol forming substance. Rapid cooling pre
`vents substantial volatilization (and hence waste) of the
`aerosol forming substance during periods when aerosol
`formation is not desired. Such heating elements also
`
`40
`
`50
`
`55
`
`60
`
`65
`
`Fontem Ex. 2018
`R.J. Reynolds Vapor Company v. Fontem Holdings 1 B.V. IPR2017-01642
`Page 12 of 23
`
`

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`20
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`25
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`4,947,875
`7
`with the aerosol forming substance, the loading of the
`?avor substance can vary from substance to substance,
`and depends upon the taste desired.
`A heat resistant, electrically insulative strip, tube or
`spacer 36, preferably is provided in order to maintain
`the heating element in place and to prevent the heating
`element from contacting itself. The insulative spacer 36
`can be a cellulosic sheet treated with ?re retardant, an
`aluminum foil having a surface coating of aluminum
`oxide, an insulative ceramic material, a heat resistant
`plastic material such as a polyimide, or the like.
`The electrical connection plug 16 preferably is manu
`factured from a resilient, electrically insulative material
`such as a thermoplastic material. The plug 16 includes
`two electrical connector pins or prongs 38, 39 con
`nected to the ends of heating element 18 via connectors
`40, 41. The pins 38, 39 engage with electrical terminals
`42, 43 located in electrical connection receptacle 44 of
`the controller 14. Plug 16 also includes a passageway 46
`through which tube 48 from pressure sensing switch 28
`extends. As shown in FIG. 1A pins 38, 39 and passage
`way 46 are offset with respect to the longitudinal axis of
`plug 16.
`A portion of the length of the electrical connection
`plug 16 preferably is circumscribed by a-collar 49 hav
`ing the form of a thermoplastic tube, which preferably
`is friction ?t around a portion of the length of the plug.
`The collar 49 in turn is secured to the remaining portion
`of the cartridge via overwrap 24 using tipping paper 52
`or other appropriate means such as adhesive, a friction
`fit, or the like. Preferably, the collar 49 includes one or
`more peripheral air inlet openings 54 which provide a
`?ow of ambient air through the cartridge during draw.
`Alternatively, the air inlet can be positioned through
`the extreme inlet end of the cartridge or elsewhere
`through the periphery of the cartridge, such that drawn
`ambient air passing through the cartridge to the mouth
`of the user passes the resistance element.
`.
`The mouthend ?lter 22 is provided for aesthetic pur
`poses. It preferably is a low efficiency filter made from
`40
`a melt blown thermoplastic such as polypropylene. For
`example, the ?lter can be manufactured by pleating a
`web of nonwoven polypropylene available from Kimb
`erly-Clark Corp. as experimental melt blown, macro?
`ber polypropylene PP-lOO-F. Alternatively, the mouth
`end ?lter 22 can be manufactured from cellulose acetate
`tow, or the like. Preferably, the ?lter material is over
`wrapped with a paper plug wrap 58.
`To maximize aerosoland ?avor delivery which oth
`erwise would be diluted by radial (i.e., outside) air in?l
`tration through the overwrap 24, one or more layers of
`non-porous paper can be used to envelop the cigarette.
`Examples of suitable non-porous papers are cigarette
`papers commercially available from Kimberly-Clark
`Corp. as KC-63-5, P878-5, P878-l6-2 and 780-63-5. If
`desired, the overwrap can be a resilient paperboard
`material, foil-lined paperboard, or the like; and the pa
`perboard can be circumscribed by a cigarette paper
`wrap.
`,
`The reusable controller 14 includes a case 26 or outer
`housing which provides a convenient and aesthetic
`holder for the user. The outer housing 26 can have a
`variety of shapes and can be manufactured from plastic,
`metal, or the like. Controller 14 includes an insulative
`receptacle 44 which includes plug-in connectors 42, 43
`for engagement with prongs 38, 39 of plug 16. Recepta
`cle 44 also includes tube 48 which is inserted into pas
`sageway 46 of plug 16 to be in air?ow communication
`
`8
`with the internal region of the cartridge. The other end
`of tube 48 is in air?ow communication with pressure
`sensing switch 28, so that changes in air pressure which
`occur within the cartridge during draw can be sensed
`by the switch.
`Controller 14 also preferably includes a control cir
`cuit 30, which is connected to a puff actuated, differen
`tial pressure sensitive switch 28 by electrically conduc
`tive wires (not shown), as well as to batteries 34A and
`34B via battery terminal 62. The control circuit 30 pref
`erably is time based. That is, the preferred current con
`trol circuit preferably is based on controlling the time
`period during draw during which current passes
`through the resistance element. This time based control,
`in turn, controls the temperature experienced by the
`resistance element and by the aerosol forming sub
`stances. Preferred pressure sensitive switches and con
`trol circuits, and their connection power source 34 and
`resistance element 18, are described in greater detail
`hereinafter with reference to FIGS. 9 and 10.
`While the heat needed to volatilize the aerosol form
`ing substance (and the ?avor forming substance in ap
`propriate cases) during a puff varies for each particular
`substance, suf?cient heat usually is necessary, during a
`puff, to heat the aerosol forming substance to a tempera
`ture above about 120° C. in order to volatilize an appro
`priate amount of the aerosol forming substance. More
`typically, a temperature above about 150° C., often
`above about 200° C., and sometimes as high as about
`300° C. to about 350° C., is necessary to volatilize ade
`quate amounts of the aerosol forming substance during
`a puff. However, it is desirable to avoid heating the
`aerosol forming substance to temperatures substantially
`in excess of about 550° C. in order to avoid degradation
`and/or excessive, premature volatilization of the aero
`sol forming substance.
`For a particular resistance heating element and a
`particular aerosol forming substance, a suf?cient cur
`rent is required, during each puff, to generate the heat
`necessary to volatilize enough aerosol forming sub
`stance to provide an adequate amount of delivered aero
`sol. For the preferred aerosol forming substances and
`the preferred carbon heating elements described herein,
`an 18 volt battery usually generates suf?cient power
`(i.e., about 18 watts) to heat the aerosol forming sub
`stance to a suitable temperature to volatilize the aerosol
`forming material almost immediately after current actu
`ation, i.e., within about 0.5 second, preferably within
`about 0.1 second. The 18 volt battery can be provided
`using two fully charged 9 volt manganese dioxide-zinc
`transistor batteries (as shown in FIG. 1) or three 6 volt
`lead acid batteries. Also useful is a silver-zinc alkaline
`battery using potassium hydroxide as an electrolyte and
`having about 12 to about 15 single cells connected in
`series, wherein the surface area of each positive elec
`trode is about 3.25 cmz. Other batteries can include
`nickel-zinc or nickel-cadmium batteries.
`In use, the user inserts the plug 16 of the cartridge 12
`into the receptacle 44 of the controller 14. Such action
`provides electrical connection of the re