O
`
`United States Patent (19)
`Morgan et al.
`
`r
`
`(54) ELECTRICAL SMOKING
`-
`(75) Inventors: Constance H. Morgan, Midlothian;
`Walter A. Nichols, Richmond, both
`of Va.
`08
`(73) Assignee: Philip Morris Incorporated, New
`York, N.Y.
`(21) Appl. No.: 12,799
`22 Filed:
`Feb. 2, 1993
`
`a v Wos asary
`
`63)
`
`56)
`
`|||||||||||||||I||
`US00524958.6A
`11) Patent Number:
`5,249,586
`(45) Date of Patent:
`Oct. 5, 1993
`
`4,393,884 7/1983 Jacobs ................................. 3 1/273
`4,431,903 2/1984 Riccio .......
`... 219/238
`4,436,100 3/1984 & J.O.
`... 31/330
`4,463,247 7/1984 Lawrence et al. ...
`... 219/236
`4,562,337 12/1985 Lawrence ........
`... 219/42
`4,570,646 2/1986 Herron .....
`... 131/185
`4,580,583 4/1986 Green, Jr. ........................... 131/330
`
`(List continued on next page.)
`FOREIGN PATENT DOCUMENTS
`1202378 1/1988 Canada .
`87/104459 2/1988 China .
`0295122 12/1988 European Pat. Off. .
`0358002 3/1990 European Pat. Off. .
`0358114 3/1990 European Pat. Off. .
`0430566 6/1991 European Pat. Off. .
`0438862 7/1991 European Pat. Off. .
`3640917A1 8/1988 Fed. Rep. of Germany .
`3";
`, 3. ERep. of Germany.
`apan .
`WO86/02528 4/1986 PCT Int'l Appl. .
`2132539 6/1984 United Kingdom .
`2148079 5/1985 United Kingdom .
`2148676 5/1985 United Kingdom .
`
`(57)
`
`ABSTRACT
`
`-
`Related U.S. Application Data
`Continuation of Ser. No. 666,926, Mar. 11, 1991, aban-
`doned.
`51) Int. Cl. ................................................ A24F 1/00
`52 U.S. Cl. .................................... 131/194; 131/270;
`131/273; 128/200.14; 128/202.21; 128/203.27
`58) Field of Search ................................ 131/194-196,
`131/270, 271, 273; 128/200.14, 202.21, 203.27
`References Cited
`y
`U.S. PATENT DOCUMENTS
`1,771,366 7/1930 Wyss et al. .
`OTHER PUBLICATIONS
`1,968,509 7/1934 Tiffany .................................. 219/38
`Excerpt from "NASA Tech Briefs,” Jul/Aug. 1988, p.
`2,057,353 10/1936 Whittemore, Jr. .
`... 219/38
`31.
`2,104,266 1/1938 McCormick .......
`... 131/12
`y9
`2,442,004 5/1948 Hayward-Butt
`128/200
`2,974,669 3/1961 Ellis ................
`... 131/172 Eistors, Keystone Carbon Company prod
`3,200,819 8/1965 Gilbert ...
`... 128/208
`3,363,633 1/1968 Weber .....
`*
`/
`Primary Examiner-V. Millin
`3,402,723 9/1968 Hu ...............
`/
`Assistant Exami
`Jennifer Dowl
`3,482,580 12/1969 Hollabaugh.
`... 131/ 178
`ssistant Examiner-Jennifer Luoyle
`... 131/173
`Attorney, Agent, or Firm-Jeffrey H. Ingerman
`3,804,100 4/1974 Fariello .......
`3,889,690 6/1975 Guarnieri....
`-
`- - - - 131/185
`4,016,061 4/1977 Wasa et al...
`... 204/192 F
`4,068,672 1/1978 Guerra ........
`An article is provided in which a replaceable tobacco
`- - - - - 13/17OA
`4,077,784 3/1978 Vayrynen ...
`flavor medium is electrically heated by a set of perma
`- - - -
`-
`- 55/146
`nent reusable heaters to evolve inhalable flavors or
`4,131,119 12/1978 Blasutti................................ 31/187
`other components in vapor or aerosol form. Each
`4,141,369 2/1979 Burruss ........................... 131/171 A
`4,164,230 8/1979 Pearlman ........................ 3/7R heater heats only a portion of the available tobacco
`4,193,411 3/1980 Faris et al. ...................... 13/17 R
`-
`4,215,708 8/1980 Bron ........
`... 131/262 B
`flavor medium so that a plurality of individual puffs of
`4,219,032 8/1980 Tabatznik et al.
`31/17OA
`tobacco flavor substance can be delivered sequentially
`4,246,913 1/1981 Ogden et al. ................... 131/171 A,
`to the smoker. The tobacco flavor medium preferably
`4,256,945 3/1981 Carter et al. ...
`219/0.75
`contains tobacco materials.
`4,259,970 4/1981 Green, Jr. ......
`... 31/330
`4,303,083 12/1981 Burruss, Jr. ......................... 13/271
`
`
`
`37 Claims, 4 Drawing Sheets
`
`Philip Morris Products, S.A.
`Exhibit 1005
`Page 001
`
`

`

`5,249,586
`Page 2
`
`U.S. PATENT DOCUMENTS
`
`4,621,649
`4,623,401
`4,637,407
`4,659,912
`4,735,217
`4,771,796
`4,776,353
`4,846,199
`4,848,376
`
`11/1986 Osterrath ............................ 131/185
`11/1986 Derbyshire et al. .................. 148/13
`1/1987 Bonanno et al. ...
`... 131/175
`4/1987 Derbyshire ...
`... 219/535
`S/1988 Gerth et al.
`... 131/273
`9/1988 Myer ..........
`... 31/273
`10/1988 Lilja et al.
`... 131/297
`7/1989 Rose ........
`... 13/329
`7/1989 Lilja et al. ........................... 131/352
`
`4,874,924 10/1989
`4,877,989 10/1989
`4,922,901 5/1990
`4,937,421 6/1989
`4,945,931 8/1990
`4,947,874 8/1990
`4,947,875 8/1990
`4,966, 171 10/1990
`4,981,522 1/1991
`4,991,606 2/1991
`5,095,921 3/1992
`5,144,962 9/1992
`
`Yamamoto et al. ................ 219/274
`Drews et al. ....................... 310/323
`Brooks et al. ...
`128A203.26
`Luthy .................................. 219/272
`Gori ............
`... 131/355
`Brooks et al.
`... 131/329
`Brooks et al. ...
`... 131/330
`Serrano et al. ..
`... 13/194
`Nichols et al. ..
`... 13 1/274
`... 131/359
`Serrano et al. ..
`Losee et al. .....
`... 31/194
`Count et al. ........................ 131/194
`
`
`
`Philip Morris Products, S.A.
`Exhibit 1005
`Page 002
`
`

`

`U.S. Patent
`
`Oct. 5, 1993
`
`Sheet 1 of 4
`
`5,249,586
`
`
`
`N
`
`Philip Morris Products, S.A.
`Exhibit 1005
`Page 003
`
`

`

`U.S. Patent
`
`Oct. 5, 1993
`
`Sheet 2 of 4
`
`5,249,586
`
`
`
`Z2 trara-4-44444 ZZZZZZZZZZOZZZZZZZZZZZZZZZZZZYZZY777
`at 4 -
`Saaaaaaaaaaaaaaaaaaac AAtcott Apace
`
`&Ysts Sea
`
`case
`naAyaar as awawaaravaravananayawasarawawawaaaaaaaa-awawayavanada
`
`ter
`- - - -
`ZZZZZZZZZZZZZZZZZ-2777.7 27777-777,777-777-7777.77
`
`7
`
`Philip Morris Products, S.A.
`Exhibit 1005
`Page 004
`
`

`

`U.S. Patent
`
`Oct. 5, 1993
`
`Sheet 3 of 4
`
`5,249,586
`
`
`
`ZZZZZZZZZZZZZZZYZZZYZZZZZZZZZZZZZZZ2
`R sessesssssssssssssssssssss-se?
`
`64 Sassaceaeace a seases 52
`
`SSSSSSSASA Saska SaaSasks are SYYYSYYYY S.
`- - - -
`ZZZZZZZZZZZZZZZZZZZZZZZZ172221.21% ZAY144
`
`y
`
`s
`
`Philip Morris Products, S.A.
`Exhibit 1005
`Page 005
`
`

`

`U.S. Patent
`
`Oct. 5, 1993
`
`Sheet 4 of 4
`
`5,249,586
`
`
`
`Philip Morris Products, S.A.
`Exhibit 1005
`Page 006
`
`

`

`1.
`
`O
`
`15
`
`ELECTRICAL SMOKENG
`
`5,249,586
`2
`It would further be desirable to be able to provide
`such an article in which variation from use to use in the
`temperature of the heating elements is minimized.
`CROSS REFERENCE TO RELATED
`SUMMARY OF THE INVENTION
`APPLICATION
`It is an object of this invention to provide an electri
`This application is a continuation of copending U.S.
`cal smoking article in which the heating elements are
`patent application Ser. No. 07/666,926, filed Mar. 11,
`reusable, and of which all disposable portions are biode
`1991, now abandoned.
`gradable.
`It is also an object of this invention to provide such an
`BACKGROUND OF THE INVENTION
`article in which electrical contact resistance between
`This invention relates to smoking articles in which
`the heaters and the source of electrical energy is mini
`tobacco flavor media are heated but not burned to re
`mized.
`lease tobacco flavors. More particularly, this invention
`It is a further object of this invention to provide such
`relates to electrical smoking articles,
`an article in which variations from use to use in the
`An electrical smoking generating article is described
`temperature of the heating elements is minimized.
`in commonly-assigned U.S. patent application Ser. No.
`In accordance with this invention there is provided a
`07/444,746, filed Dec. 1, 1989, now U.S. Pat. No.
`smoking article for delivering to a smoker an inhalable
`5,060,671, which was copending with parent applica
`tobacco flavor substance. The article includes a plural
`ity of electrical heating means disposed in a cavity, a
`tion Ser. No. 07/666,926, filed Mar. 11, 1991, and which
`20
`is hereby incorporated by reference in its entirety. That
`source of electrical energy for powering the plurality of
`application describes an electrical smoking article
`electrical heating means, control means for applying the
`which is provided with a disposable set of electrical
`electrical energy to the electrical heating means to heat,
`at any one of a predetermined number of times, at least
`heating elements on each of which is deposited an indi
`vidual charge of tobacco flavor medium containing, for
`one but fewer than all of the plurality of electrical heat
`25
`ing means, and a removable portion of tobacco flavor
`example, tobacco or tobacco-derived material. The
`medium received in the cavity in contact with the plu
`disposable heater/flavor unit is mated to a more or less
`rality of electrical heating means. When any one of the
`permanent unit containing a source of electrical energy
`plurality of electrical heating means is activated, a re
`such as a battery or capacitor, as well as control cir
`spective fraction of the removable portion of tobacco
`cuitry to actuate the heating elements in response to a
`30
`flavor medium in contact with that one of the heating
`puff by a smoker on the article or the depression of a
`means is heated, delivering a predetermined quantity of
`manual switch. The circuitry is designed so that at least
`tobacco flavor substance to the smoker.
`one but less than all of the heating elements are actuated
`for any one puff, so that a pre-determined number of
`BRIEF DESCRIPTION OF THE DRAWINGS
`35
`puffs, each containing a premeasured amount of to
`The above and other objects and advantages of the
`bacco flavor substance, is delivered to the smoker. The
`invention will be apparent upon consideration of the
`circuitry also preferably prevents the actuation of any
`following detailed description, taken in conjunction
`particular heater more than once, to prevent overheat
`with the accompanying drawings, in which like refer
`ing of the tobacco flavor medium thereon and conse
`40 ence characters refer to like parts throughout, and in
`quent production of undesired compounds yielding off
`which:
`tastes.
`FIG. 1 is a perspective view of an electrical smoking
`In such an article, the heating elements are disposed
`article according to this invention;
`of along with the spent tobacco flavor medium. This
`FIG. 2 is a partially fragmentary, exploded perspec
`results in increased costs to the smoker, who must buy
`tive view of the electrical smoking article of FIG. 1;
`45
`new heating elements with each refill of tobacco flavor
`FIG. 3 is a radial cross-sectional view of the electrical
`medium. The volume of material disposed of is also
`smoking article of FIGS. 1 and 2, taken from line 3-3
`greater when the heating elements must be disposed of.
`of FIG. 2;
`In addition, when the heating elements are not per
`FIG. 3A is a radial cross-sectional view of the electri
`manently attached to the article, there is sometimes
`cal smoking article of FIGS. 1-3, taken from line
`50
`excessive contact resistance where the removable heat
`3A-3A of FIG. 1;
`ers are electrically connected to the source of electrical
`FIG. 4 is a longitudinal cross-sectional view of the
`energy, resulting in increased power consumption.
`flavor cartridge receiving cavity of the electrical smok
`Also, when the heating elements are disposable, the
`ing article of FIGS. 1-3A, taken from line 4-4 of FIG.
`resistance may vary from heater to heater, resulting in
`3;
`variations in power consumption when in turn lead to
`FIG. 5 is a radial cross-sectional view similar to FIG.
`variations in temperature. As it is the temperature to
`3 of the electrical smoking article of the invention,
`which the tobacco flavor generating medium is heated
`showing an alternative heater embodiment;
`that determines the characteristics of the tobacco flavor
`FIG. 6 is a longitudinal cross-sectional view of the
`flavor cartridge receiving cavity of the electrical smok
`substance, those characteristics will also vary.
`It would therefore be desirable to be able to provide
`ing article of FIG. 5, taken from line 6-6 of FIG. 5;
`an electrical smoking article in which the heating ele
`FIG. 7 is a radial cross-sectional view similar to
`ments are reusable, and of which all disposable portions
`FIGS. 3 and 5 of the electrical smoking article of the
`are biodegradable.
`invention, showing another alternative heater embodi
`It would also be desirable to be able to provide such
`ment;
`FIG. 8 is a longitudinal cross-sectional view of the
`an article in which electrical contact resistance between
`flavor cartridge receiving cavity of the electrical smok
`the heaters and the source of electrical energy is mini
`ing article of FIG. 7, taken from line 8-8 of FIG. 7;
`Inized.
`
`55
`
`65
`
`Philip Morris Products, S.A.
`Exhibit 1005
`Page 007
`
`

`

`10
`
`15
`
`25
`
`5,249,586
`3
`4.
`FIG. 9 is a perspective view of an alternative embodi
`heaters should consume between about calorie and
`ment of a flavor cartridge according to the present
`about 6 calories, given the limitations of power sources.
`Heaters having such characteristics preferably have a
`invention; and
`ratio of active surface area (surface area in contact with
`FIG. 10 is an end elevational view of the flavor car
`the tobacco flavor medium) to mass of between about 3
`tridge of FIG. 9, taken from line 10-10 of FIG. 9.
`mm2/mg and about 6 mm/mg, an active surface area of
`DETAILED DESCRIPTION OF THE
`between about 3 mm2 and about 50 mm, a mass of
`INVENTION
`between about 1 mg and about 30 mg, and a resistance
`of between about 0.5 ohm and 3.0 ohms. More prefera
`An electrical smoking article according to the present
`bly, the heaters should have an active surface area of
`invention can be used, for example, to simulate a ciga
`between about 3 mm2 and about 20mmand a resistance
`rette. In such a case, the tobacco flavor medium would
`of between about 1.0 ohm and 1.6 ohms. These require
`be a material containing tobacco or tobacco derivatives.
`ments are interrelated, because heater power consump
`In accordance with the invention, the electrical article
`tion is determined by resistance, which in turn is deter
`would include a removable disposable portion which
`mined by resistivity and size.
`included the tobacco flavor medium and, if desired, a
`The materials of which the heaters are made are
`filter, and a reusable "permanent' portion including a
`chosen to assure reliable repeated uses of up to 3,600
`source of electrical energy, a set of reusable heating
`on/off cycles without failure. The heater materials are
`elements, and control circuitry for energizing the heat
`also chosen based on their reactivities, to assure that
`ers in an appropriate sequence, in response to manual
`they will not react with the tobacco flavor medium at
`20
`actuation or puff-induced actuation. Suitable control
`any temperature likely to be encountered to form any
`circuitry is described in above-incorporated copending,
`undesired compounds. Similarly, the heaters themselves
`commonly-assigned patent application Ser. No.
`should not evolve any undesired compounds when
`07/444,746, filed Dec. 1, 1989, now U.S. Pat. No.
`heated out of the presence of the tobacco flavor me
`5,060,671.
`dium. Alternatively, heater materials that might other
`The reusable or permanent portion includes a cavity
`wise give rise to undesired compounds could be encap
`at the mouth end thereof for insertion of the disposable
`sulated in an inert heat-conducting material such as a
`portion. The reusable heaters are disposed in the cavity
`suitable ceramic material.
`in such a way that they make thermal contact with the
`Based on these criteria, preferred materials for the
`disposable portion when the disposable portion is in
`electric heating means of the present invention include
`30
`serted into the cavity. This can be accomplished by
`carbon, graphite, stainless steel, tantalum, metal ceramic
`having the heaters protrude from the sides of the cavity
`matrices, and metal alloys, such as aluminum alloys,
`and making the disposable portion compressible, so that
`iron alloys, and chromium alloys. Suitable metal
`the heaters press into the material. Alternatively, the
`ceramic matrices include silicon carbide aluminum and
`heaters can protrude from the end of the cavity, so that
`silicon carbide titanium. Of the listed materials, stainless
`35
`they actually pierce and extend into the disposable por
`steel and the aluminum, iron or chromium alloys should
`tion.
`be encapsulated in a suitable ceramic material because
`When reusable heaters are used, it is important that
`of their reactivity. Suitable ceramic materials for encap
`they be cleaned before each use. Otherwise, residues
`sulation include silica, alumina, and sol gels.
`from the previous use, which might include partially
`A particularly preferred material for use in the elec
`oxidized, pyrolized or thermally decomposed constitu
`trical heating means of this invention is tantalum.
`ents of the tobacco flavor generating medium, might be
`A first preferred embodiment of an electrical smoking
`reheated, possibly giving rise to undesired compounds
`article 10 according to the invention is shown in FIGS.
`and off tastes being delivered to the smoker. Such resi
`1-4. Article 10 includes reusable or "permanent' por
`dues are not of concern when the heaters are part of the
`tion 20 and disposable filter/flavor portion or cartridge
`45
`disposable portion because they are never reheated, but
`21 which is received in a cavity 30 at the mouth end of
`may be of concern where reusable heaters are provided.
`portion 20.
`In the present invention, the cleaning of the heaters is
`Reusable portion 20 includes, at the end remote from
`accomplished by the wiping action of the disposable
`the mouth end, a power source 22, which could include
`portion against the heaters as the disposable portion is
`a battery, a capacitor or both. The battery could be
`50
`inserted. Thus the insertion end of the disposable por
`replaceable, rechargeable or both. If the battery is re
`chargeable, or if power source 22 is a capacitor alone,
`tion pushes any residues on the heater surfaces toward
`the mouth end of the cavity, to, and preferably past, the
`then article 10 is provided with charging contacts 11 on
`ends of the heaters. For this reason, the disposable por
`its outer surface, for connection to an external power
`tion, while compressible, should be relatively firm, and
`supply (not shown) for charging power source 22.
`55
`the heaters should preferably have a smooth surface
`Power source 22 provides power for heating elements
`finish to assure that the wiping action is effective.
`23, which are energized under the control of control
`The parameters of the heaters are chosen to allow
`circuit 24, which is in turn actuated by pushbutton 25 or
`by a puff-actuated sensor (not shown). Indicators 26,
`delivery of an effective amount of tobacco flavor sub
`stance-e.g., an aerosol containing tobacco flavors-to
`which could be light-emitting diodes or other visual
`the consumer under standard conditions of use. For
`indicators, reflect the status of the various heaters 23.
`example, it may be desirable to deliver 2 mg of aerosol
`The functions of power source 22, control circuit 24,
`pushbutton 25 (or a puff-actuated sensor), and indica
`to a smoker during a 35 ml puff having a two-second
`tors 26 are described in more detail in above-incor
`duration.
`porated copending, commonly-assigned patent applica
`It has been found that in order to achieve such deliv
`65
`ery, the heaters should be able to reach a temperature of
`tion Ser. No. 07/444,746, filed Dec. 1, 1989, now U.S.
`Pat. No. 5,060,671. Portion 20 is preferably covered by
`between about 150° C. and about 500 C. when in
`cigarette wrapping paper 31, to give it the appearance
`contact with the tobacco flavor medium. Further, the
`
`Philip Morris Products, S.A.
`Exhibit 1005
`Page 008
`
`

`

`O
`
`15
`
`5,249,586
`5
`6
`could be inserted flush into cavity 30, and a separate
`of a conventional cigarette. Perforations 12 may be
`provided in the wall of portion 20 to allow outside air to
`ejection mechanism (not shown) could be provided.
`Whatever length portion 21 is made, the relative lengths
`be drawn in during puffing, or outside air may be drawn
`through all of portion 20 via openings (not shown) at its
`of segments 27, 28 preferably should be such that all of
`filter segment 28 is closer to the mouth end of cavity 30
`far end 13.
`In this embodiment, heating elements 23 are linear,
`than the ends 40 of heating elements 23, so that no en
`extending from a point slightly spaced away from the
`ergy is wasted heating filter segment 28.
`mouth end of cavity 30 to a point slightly spaced away
`As discussed above, a wiping action cleans residue
`from previous uses off heating elements 23 as each new
`from the rod end of cavity 30. As seen in FIG. 4, heat
`disposable portion 21 is inserted, and that preferably is
`ing elements 23 are bowed slightly away from the wall
`aided by smooth surface finish 41 on the surface of
`of cavity 30, for reasons to be discussed below. At one
`heating elements 23. (Although drawn separately from
`of the two ends, all of heating elements 23 are con
`elements 23, surface finish 41 need not be, and prefera
`nected in common to ground, while at the other end
`bly is not, a separate layer.) The resilience of firm but
`each element 23 is connected separately to control cir
`compressible portion 21 assures firm contact for the
`cuitry 24 for individual actuation of heating elements
`wiping action. Preferably also, the ends 42 of heating
`23. The curvature of ends 40 of heating elements 23 at
`the mouth end of cavity 30 provides a lead-in for the
`elements 23 remote from the mouth end are connected
`insertion of disposable portion 21. Heating elements 23
`to the side wall of cavity 30 adjacent to, but spaced
`are preferably distributed substantially uniformly
`away from, end wall 43 of cavity 30. That allows the
`residue that is wiped off heating elements 23 to be
`around the circumference of cavity 30, and should pref
`20
`erably be spaced apart sufficiently that the regions of
`pushed past ends 42 of heating elements 23 so that resi
`disposable portion 21 heated by neighboring heating
`due is not reheated.
`elements 23 do not overlap, which could lead to reheat
`As discussed above, in embodiment 10 of FIGS. 1-4,
`ing and the production of undesired compounds and off
`the electrical connections to heating elements 23 are
`made at both ends 40, 42 thereof, requiring the exten
`25
`tastes.
`Disposable portion 21 preferably includes a flavor
`sion of wires or other conductors to the mouth end of
`cavity 30. That requirement is eliminated in a more
`segment 27 and a filter segment 28, attached by a plug
`particularly preferred embodiment 50, which is identi
`wrap or other fastening means (not shown). Filter seg
`cal to embodiment 10 except for the arrangement of
`ment 28 is preferably a conventional cellulose acetate
`filter segment, and preferably is very short, being pro
`heating elements 51 as illustrated in FIGS. 5 and 6.
`30
`vided mostly for the sake of appearance and to give
`Each heating element 51 is in the shape of an elon
`gated “U”, each having both of its ends 52, 53 con
`article 10 a "mouth feel' similar to a conventional ciga
`nected to the side wall of cavity 30 adjacent end wall 43
`rette.
`of cavity 30. Each respective end 52 is individually
`Flavor segment 27 can be any material that liberates
`connected to control circuitry 24 for individual actua
`flavors when hot air passes over or through it. Prefera
`bly, flavor segment 27 is a cylindrical portion of an
`tion of heating elements 51, while ends 53 are connected
`in common to ground. While ends 54 adjacent the
`extruded open-cell foamed tobacco product of the kind
`mouth end of cavity 30 are not electrically connected,
`described in commonly-assigned U.S. Pat. No.
`4,510,950, which is hereby incorporated by reference in
`and thus need not touch the side wall of cavity 30, they
`its entirety, except that approximately 10% of an aero
`are nonetheless turned toward the side wall of cavity
`sol precursor such as glycerine is added to the composi
`30, as shown in both FIGS. 5 and 6, to provide a lead-in
`for disposable portion 21 as discussed above. It should
`tion. It is desirable to add an aerosol precursor to de
`be noted that in FIG. 6, the uppermost and lowermost
`liver the tobacco flavor substance as an aerosol, so that
`elements 51 are shown cut through their U-shaped tips
`when the consumer exhales the tobacco flavor sub
`stance, the visible condensed aerosol may minic the
`54.
`45
`appearance of cigarette smoke.
`In another embodiment 70 shown in FIGS. 7 and 8,
`heating elements 71 are spaced somewhat further from
`The diameter of filter/flavor portion 21 is at most
`the wall of cavity 30, and each is provided with a some
`equal to the inner diameter of cavity 30, and should be
`what sharper “V' tip 72, as well as with fold 73 to
`at least somewhat greater than the diameter of the cylin
`increase their rigidity. In this way, heating elements 71
`drical space between heating elements 23, which are
`actually pierce and extend into disposable portion 21 to
`bowed out from the wall of cavity 30 as discussed
`provide the desired intimate thermal contact. The open
`above, so that elements 23 press into flavor segment 27
`cell foam structure described above is particularly well
`for intimate thermal contact. To that end, flavor seg
`ment 27 should be firm but compressible. The open-cell
`suited for such an embodiment. In this embodiment,
`because heating elements 71 are spaced further from the
`foamed structure described in above-incorporated U.S.
`Pat. No. 4,510,950 is particularly well-suited for that
`side wall of cavity 30, ends 52, 53 are not attached to the
`side wall of cavity 30, but to its end wall 43. Preferably,
`purpose, but other compressible structures may be used.
`The compression of flavor segment 27 by heating
`the connections of ends 52, 53 to end wall 43 are made
`through spacers 80 which are not conductive of either
`elements 23 is illustrated in FIG. 3A, which shows a
`heat or electricity. In this way, the wiping action re
`radial cross-sectional view of article 10 with disposable
`60
`portion 21 inserted. FIG. 3A also shows regions 32 of
`ferred to above wipes residue past ends 52, 53 and onto
`flavor segment 27 adjacent heaters 23, each region 32
`spacers 80, where the residues are not reheated.
`representing that fraction of segment 27 that is heated
`An alternative embodiment of flavor segment 27 of
`disposable portion 21 is shown in FIGS. 9 and 10. Fla
`by each respective heater 23 to provide an individual
`vor segment 90 includes a fiber bundle 91 around which
`charge of tobacco flavor substance.
`65
`is wrapped a layer 92 of metallic foil, such as aluminum
`The length of portion 21 is preferably such that some
`part of filter segment 28 protrudes from cavity 30 to aid
`foil, onto which has been coated a slurry 93 of tobacco
`flavor medium. Fiber bundle 91 gives segment 90 the
`removal of spent portions 21. However, portion 21
`
`35
`
`50
`
`55
`
`Philip Morris Products, S.A.
`Exhibit 1005
`Page 009
`
`

`

`10
`
`15
`
`5,249,586
`8
`7
`means, providing intimate thermal contact therebe
`necessary compressibility. This alternative avoids the
`inefficient use of tobacco that occurs in segment 27,
`tween.
`where the tobacco foam region 33 (FIG. 3A) in the
`6. The article of claim 1 wherein:
`each of said plurality of electrical heating means pro
`center of segment 27 provides bulk and compressibility
`trudes into said cavity; and
`but is never heated to deliver flavor to the smoker.
`said removable portion is compressible; whereby:
`Furthermore, if this embodiment 90 is used, fiber bundle
`each of said plurality of electrical heating means ex
`91 could be made of cellulose acetate or other suitable
`tends into said removable portion, providing inti
`filter material, and could be extended to form filter
`segment 28, thereby providing disposable portion 21 as
`mate thermal contact therebetween.
`a unitary body.
`7. The article of claim 1 wherein:
`said cavity has an insertion end through which said
`Thus it is seen that an electrical smoking article is
`removable portion is inserted and a far end remote
`provided in which the heating elements are reusable,
`from said insertion end; and
`and of which all disposable portions can be biodegrad
`when said removable portion is inserted into said
`able. In addition, electrical contact resistance between
`cavity, said removable portion wipes from each of
`the heaters and the source of electrical energy is elimi
`said plurality of electrical heating means any resi
`nated, as the heaters are permanently attached. One
`due remaining from a previously heated removable
`skilled in the art will appreciate that the present inven
`portion.
`tion can be practiced by other than the described em
`8. The article of claim 7 wherein each of said plurality
`bodiments, which are presented for purposes of illustra
`of electrical heating means is spaced from said far end,
`tion and not of limitation, and the present invention is
`whereby when said removable portion is inserted into
`limited only by the claims which follow.
`said cavity, said removable portion wipes said residue
`What is claimed is:
`beyond each of said plurality of electrical heating means
`1. An electrical smoking article for delivering to a
`in the direction of said far end.
`smoker an inhalable tobacco flavor substance, said arti
`cle comprising:
`9. The article of claim 7 wherein said removable
`portion is compressible.
`a plurality of electrical heating means disposed in a
`cavity;
`10. The article of claim 1 wherein said tobacco flavor
`medium comprises an extruded tobacco material.
`a source of electrical energy for powering said plural
`11. The article of claim 10 wherein said extruded
`ity of electrical heating means;
`control means for applying said electrical energy to
`tobacco material is a tobacco foam material.
`30
`12. The article of claim 11 wherein said tobacco foam
`said electrical heating means to heat, at any one of
`material is an open-cell foam.
`a predetermined number of times, at least one but
`fewer than all of said plurality of electrical heating
`13. The article of claim 11 wherein:
`said tobacco foam material comprises an aerosol
`means; and
`forming material; and
`a removable portion of tobacco flavor medium re
`35
`ceived in said cavity in proximity to said plurality
`when said tobacco flavor medium is heated, an aero
`sol comprising tobacco components is formed.
`of electrical heating means; whereby:
`when any one of said plurality of electrical heating
`14. The article of claim 13 wherein said aerosol-form
`ing material comprises glycerine.
`means is activated, a respective fraction of said
`15. The article of claim 1 wherein:
`removable portion of tobacco flavor medium in
`said tobacco flavor medium comprises tobacco; and
`contact with said one of said heating means is
`heated, delivering a predetermined quantity of
`when said tobacco flavor medium is heated, a to
`bacco flavor substance comprising tobacco compo
`tobacco flavor substance to said smoker.
`nents is formed.
`2. The article of claim 1 wherein said removable
`16. The article of claim 1 wherein:
`portion of tobacco flavor medium contains a sufficient
`45
`said tobacco flavor medium comprises an aerosol
`quantity of tobacco flavor medium to deliver said pre
`forming material; and
`determined quantity of tobacco flavor substance to said
`when said tobacco flavor medium is heated, an aero
`smoker once for each activation of each of said plurality
`sol is formed.
`of electrical heating means; wherein:
`17. The article of claim 16 wherein said aerosol-form
`said removable portion is spent after one activation of
`50
`ing material comprises glycerine.
`each of said plurality of electrical heating means;
`18. The article of claim 17 wherein said aerosol-form
`and
`ing material further comprises water.
`said removable portion is replaceable by said smoker
`19. The article of claim 16 wherein said aerosol-form
`when it is spent.
`ing material comprises water.
`3. The article of claim 1 wherein said cavity and said
`removable portion are substantially cylindrical and
`20. The article of claim 1 wherein:
`said tobacco flavor medium comprises tobacco and
`have substantially the same diameter.
`an aerosol-forming material; and
`4. The article of claim 3 wherein said removable
`when said tobacco flavor medium is heated, an aero
`portion is longer than said cavity and has an end pro
`sol comprising tobacco components is formed.
`truding from said cavity, said protruding end providing
`21. The article of claim 20 wherein said tobacco fla
`a grip for said smoker for insertion and removal of s