United States Patent (19)
`Collins et al.
`
`USOO5865.185A
`Patent Number:
`11
`(45) Date of Patent:
`
`5,865,185
`*Feb. 2, 1999
`
`54) FLAVOR GENERATING ARTICLE
`
`75 Inventors: Alfred L. Collins, Powhatan; Mary
`Ellen Counts, Richmond; Amitabh
`
`1968,509 7/1934 Tiffany ...................................... 219/38
`2,057,353 10/1936 Whittemore, Jr. .
`... 219/38
`2,104.266
`1/1938 McCormick .......
`... 131/12
`2,442,004 5/1948 Hayward-Butt
`... 128/200
`
`Das, Midlothian; Seetharama C. Deevi,
`
`2.974,669 3/1961 Ellis - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 131/172
`
`Midlothian: Grier S. Fleischhauer
`s
`s
`Midlothian; Charles T. Higgins; Willie
`G. Houck, Jr., both of Richmond; Billy
`J. Keen, Jr., Chesterfield; Robert E.
`
`List
`t
`d
`t
`(List continued on next page.)
`FOREIGN PATENT DOCUMENTS
`
`Lee, III, Richmond; A. Clifton Lilly,
`
`sRE 3.
`
`*
`
`Notice:
`
`ada - - - - - - - - - - - - - - - - - - - - - - - - - - - - B23K 3/02
`a
`
`O 295 122 12/1988 European Pat. Off. ........ A24F 47/OO
`0.358 002 3/1990 European Pat. Off. ........ A24F 47/OO
`0.358 114 3/1990 European Pat. Off. ....... A61M 15/OO
`O 430 566 A2 6/1991 European Pat. Off. ........ A24F 47/OO
`0 438 862 A2 7/1991 European Pat. Off. ........ A24F 47/OO
`3 640917 8/1988 Germany ....................... A45D 34/O2
`3 735 704 5/1989 Germany ......................... A61L 9/03
`61-68061
`4/1986 Japan................. A61M 15/06
`: 3.
`.
`3. As E. - - - - - - - - - - - - - E. s:
`2 148676 5/1985 United Kingdom ............. HO5B 3/28
`WO 86/02528 5A1986 WIPO ............................ A24B 15/18
`WO95/05094 2/1995 WIPO ............................. A24F 47/OO
`
`e
`
`ngdom ......
`
`- - -
`
`Primary Examiner V. Millin
`ASSistant Examiner William J. Deane, Jr.
`Attorney, Agent, or Firm-Charles E. B. Glenn; James E.
`Schardt; James T. Moore
`57
`ABSTRACT
`A Smoking
`le is provided
`hich a replaceable tob
`Smoking article is provided in which a replaceable tobacco
`flavor unit containing tobacco flavor material is electrically
`heated b y a set of permanent reusable heaters to evolve
`flavors or other components in vapor or aerosol form for
`delivery to a Smoker. Each heater heats only a portion of the
`available tobacco flavor material so that a plurality of
`individual puffs of tobacco flavor Substance can be delivered
`quentially to th
`ker. The replaceable tob
`f
`unit can also include a filter to reduce the effect of residual
`aeroSol which Settles or condenses on the permanent por
`tions of the article and which can result in undesirable flavor
`generation when reheated. A method and apparatus for
`manufacturing the replaceable tobacco flavor unit is also
`provided.
`
`SeculentiallW to the Smoker. The replaceable tobacco flavor
`
`75 Claims, 12 Drawing Sheets
`
`ENGE R Jr.,
`Ichmond; Hugn J. McLanery;
`Constance H. Nichols, both of
`Midlothian; Wynn R. Raymond,
`Chesterfield; Robert L. Ripley; Renzer
`R. Ritt, Sr., both of Richmond; G.
`Robert Scott, Midlothian; F. Murphy
`Sprinkel, Glen Allen; Michael L.
`Watkins, Chester; Susan E. Wrenn,
`SR Earl V. Utsch,
`ICl IOInlan, all OI Va.
`73 Assignee: Philip Morris Incorporated, New
`York, N.Y.
`The portion of the term of this patent
`Subsequent to Sep. 10, 2013, has been
`disclaimed.
`21 Appl. No.: 448,906
`22 Filed
`May 24, 1995
`illed:
`ay 24,
`Related U.S. Application Data
`-
`-
`-
`60 Division of Ser. No. 943,504, Sep. 11, 1992, Pat. No.
`5,505,214, which is a continuation-in-part of Ser. No. 666,
`926, Mar. 11, 1991, abandoned.
`6
`A24F 1700
`51 Int. Cl
`52) U.S. Cl. .......................... 131/194; 131/271; 131/329;
`128/200.14; 128/202.21; 128/203.27
`58 Field of Search ..................................... 131/194,329,
`131/271; 128/202.21, 203.27, 200.14
`References Cited
`U.S. PATENT DOCUMENTS
`7/1930 Wyss et al..
`
`O
`
`-1 - O
`
`- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
`
`56)
`
`1,771,336
`
`
`
`Philip Morris Products, S.A.
`Exhibit 1022
`Page 001
`
`

`

`5,865,185
`Page 2
`
`U.S. PATENT DOCUMENTS
`
`3,200,819 8/1965 Gilbert .................................... 128/208
`35. E. S."
`is is
`
`1/1987 Bonnano et al. ....................... 131/175
`4,637,407
`4,659,912 4/1987 Derbyshire .............................. 219/535
`4,682,010 7/1987 Drapeau et al. ........................ 219/381
`4,686,353 8/1987 Spector ......
`... 219/275
`
`3.402.723 9/1968 Hu ...........
`
`131/185
`
`4,692,590 9/1987 Spector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 219/275
`
`3,482,580 12/1969 Hollebaugh ...
`
`... 131/ 178
`
`s: R sian - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2.
`
`3,496.336 2/1970 Hingorany et al.
`
`... 219/464
`
`... 219/464
`7/1971 Gartner ..........
`3.591,753
`... 131/2
`3,608,560 9/1971 Briskin ...
`... 131/2
`3,738,374 6/1973 Bennett ......
`... 131/8
`3,744,496 7/1973 McCarty et al.
`... 131/173
`3,804,100 4/1974 Fariello ......
`... 131/185
`3,889,690 6/1975 Guarnieri
`... 204/192
`4,016,061
`4/1977 Wasa et al.
`... 131/170
`4,068,672
`1/1978 Guerra ...
`... 55/146
`4,077,784 3/1978 Vayrynen
`... 131/187
`4,131,119 12/1978 Blasutti ...
`... 131/171
`4,141,369 2/1979 Buurruss ...
`... 131/171
`4,164,230 8/1979 Pearlman ...
`... 131/171
`4,193,411
`3/1980 Faris et al. .....
`... 219/216
`4,194,108 3/1980 Nakajima et al.
`... 219/216
`4,203,025 5/1980 Nakatani et al. .
`... 131/262
`4,215,708 8/1980 Bron ..................
`131/170
`4,219,032 8/1980 Tabatznik et al.
`... 131/771
`4,246,913
`1/1981. Ogden et al. .....
`219/10.75
`4,256,945
`3/1981 Carter et al. ...
`... 219/216
`4,259,564 3/1981. Ohkubo ...
`... 131/330
`4,259,970 4/1981 Green, Jr.
`... 131/271
`4,303,083 12/1981 Burruss, Jr.
`... 131/359
`4,319,591
`3/1982 Keith et al. .
`... 131/273
`4,393,884 7/1983 Jacobs .....
`... 219/238
`4,431,903 2/1984 Riccio .....
`... 131/330
`4,436,100 3/1984 Green, Jr. ...
`... 219/236
`4,463,247 7/1984 Lawrence et al.
`4,505,282 3/1985 Cogbill et al. .......................... 131/334
`4,562,337 12/1985 Lawrence ................................ 219/421
`4,570,646 2/1986 Herron ...
`... 131/185
`4,580,583 4/1986 Green, Jr. ................................ 131/330
`4,621,649 11/1986 Osterrath ................................. 131/185
`4,623,401 11/1986. Derbyshire et al.
`148/13
`4,629,604 12/1986 Spector ................................... 422/124
`
`
`
`2 : - - 2
`
`-
`
`- - - - - - - - - - - - - - - - - - - - - - - - - - - - -
`
`4,771,796 9/1988 Myer et al. ............................. 131/273
`4,776,353 10/1988 Lilja et al. .
`... 131/297
`4,837,421
`6/1989 Luthy ......
`... 219/272
`4,846,199 7/1989 Rose ........
`... 131/329
`4,848,376
`7/1989 Lilja et al. .............................. 131/352
`4,874,924 10/1989 Yamamoto et al. .................... 219/274
`4,877,989 10/1989 Drews et al. ........................... 3.10/323
`4,922.901
`5/1990 Brooks et al.
`128/203.26
`4,945,931
`8/1990 Gori ........................................ 131/335
`4,947.874 8/1990 Brooks et al.
`... 131/329
`4,947.875
`8/1990 Brooks et al. .
`... 131/330
`4,966,171 10/1990 Seranno et al.
`... 131/194
`4,981.522
`1/1991 Nichols et al. ...
`... 131/274
`4,991,606
`2/1991 Serrano et al.
`... 131/359
`4,998.541
`3/1991 Perfetti et al. .
`... 131/336
`5,016,656
`5/1991 McMurtrie ...
`... 131/364
`5,040,552
`8/1991 Schleich et al. ..
`... 131/359
`5,042,510
`8/1991 Curtiss et al. .
`... 131/273
`5,060.671 10/1991 Counts et al. .
`... 131/329
`5,076.296 12/1991 Nystrom et al.
`... 131/359
`5,093,894 3/1992 Deevi ............
`... 392/390
`5,095,921
`3/1992 Losee et al.
`... 131/194
`5,144.962 9/1992 Counts et al. ...
`... 131/194
`5,159,940 11/1992 Hayward et al. .
`... 131/194
`5,179.966
`1/1993 Losee et al. ......
`... 131/351
`5,188,130 2/1993 Hajaligol et al.
`... 131/359
`5,224,498
`7/1993 Deevi et al. ...
`... 131/194
`5,235,157 8/1993 Blackburn ............................... 219/268
`5,249,586 10/1993 Morgan et al. ......................... 131/194
`5,269,327 12/1993 Counts et al. .
`... 131/194
`5,274,214 12/1993 Blackburn ............................... 219/268
`5,285,050 2/1994 Blackburn ............................... 219/268
`5,388,594 2/1995 Counts et al.
`131/194X
`5,479,948
`1/1996 Counts et al. .......................... 131/194
`
`Philip Morris Products, S.A.
`Exhibit 1022
`Page 002
`
`

`

`U.S. Patent
`
`Feb. 2, 1999
`
`Sheet 1 of 12
`
`5,865,185
`
`
`
`Philip Morris Products, S.A.
`Exhibit 1022
`Page 003
`
`

`

`U.S. Patent
`
`Feb. 2, 1999
`
`Sheet 2 of 12
`
`5,865,185
`
`
`
`Philip Morris Products, S.A.
`Exhibit 1022
`Page 004
`
`

`

`U.S. Patent
`
`Feb. 2, 1999
`
`Sheet 3 of 12
`
`5,865,185
`
`
`
`
`
`
`
`
`
`
`Lan --------¬[×
`? (,)
`
`No.===)/Z
`
`Philip Morris Products, S.A.
`Exhibit 1022
`Page 005
`
`

`

`Philip Morris Products, S.A.
`Exhibit 1022
`Page 006
`
`

`

`U.S. Patent
`
`Feb. 2, 1999
`
`Sheet S of 12
`
`5,865,185
`
`
`
`Philip Morris Products, S.A.
`Exhibit 1022
`Page 007
`
`

`

`U.S. Patent
`
`Feb. 2, 1999
`
`Sheet 6 of 12
`
`5,865,185
`
`
`
`Philip Morris Products, S.A.
`Exhibit 1022
`Page 008
`
`

`

`Philip Morris Products, S.A.
`Exhibit 1022
`Page 009
`
`

`

`U.S. Patent
`
`
`
`Feb. 2, 1999
`
`Sheet 8 of 12
`
`5,865,185
`
`Philip Morris Products, S.A.
`Exhibit 1022
`Page 010
`
`

`

`U.S. Patent
`
`Feb. 2, 1999
`
`Sheet 9 of 12
`
`5,865,185
`
`AaaZZZZZZZZZZZZZZZZZZZZZZza
`
`
`
`
`
`
`
`
`
`6-162A
`
`2.
`Z2 N7
`62B
`62
`S4 ZZZZZZZZZZZZZZZ 42
`Es) NN
`22 BSSSSSS is si?ts, is 35
`
`
`
`
`
`Philip Morris Products, S.A.
`Exhibit 1022
`Page 011
`
`

`

`U.S. Patent
`
`Feb. 2, 1999
`
`Sheet 10 of 12
`
`5,865,185
`
`
`
`Philip Morris Products, S.A.
`Exhibit 1022
`Page 012
`
`

`

`U.S. Patent
`
`Feb. 2, 1999
`
`Sheet 11 of 12
`
`5,865,185
`
`
`
`
`
`Þý SP)~~SP
`v661)
`
`Philip Morris Products, S.A.
`Exhibit 1022
`Page 013
`
`

`

`U.S. Patent
`
`Feb. 2, 1999
`
`Sheet 12 of 12
`
`5,865,185
`
`
`
`Philip Morris Products, S.A.
`Exhibit 1022
`Page 014
`
`

`

`1
`FLAVOR GENERATING ARTICLE
`
`5,865,185
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`This application is a divisional application of Ser. No.
`07/943,504 filed Sep. 11, 1992, now U.S. Pat. No. 5,505,
`214, which is a continuation-in-part of commonly-assigned
`U.S. patent application Ser. No. 07/666,926, filed Mar. 11,
`1991, now abandoned in favor of filewrapper continuation
`application Ser. No. 08/012,799, filed Feb. 2, 1993, now
`U.S. Pat. No. 5,249,586 issued Oct. 15, 1993 which is
`hereby incorporated by reference in its entirety, which is a
`continuation of application Ser. No. 07/666,926 filed Mar.
`11, 1991, now abandoned.
`
`5
`
`15
`
`BACKGROUND OF THE INVENTION
`This invention relates to Smoking articles in which
`tobacco flavor media are heated to release tobacco flavors.
`More particularly, this invention relates to electrically
`heated Smoking articles.
`An electrically-heated Smoking article is described in
`commonly-assigned U.S. Pat. No. 5,060,671, which is
`hereby incorporated by reference in its entirety. That patent
`describes an electrically-heated Smoking article which is
`provided with a disposable Set of electrical heating elements
`on each of which is deposited an individual charge of
`tobacco flavor medium containing, for example, tobacco or
`tobacco-derived material. The disposable heater/flavor unit
`is mated to a more or leSS permanent unit containing a Source
`of electrical energy Such as a battery or capacitor, as well as
`control circuitry to actuate the heating elements in response
`to a puff by a smoker on the article or the depression of a
`manual Switch. The circuitry is designed So that at least one
`but leSS than all of the heating elements are actuated for any
`one puff, So that a predetermined number of puffs, each
`containing a pre-measured amount of tobacco flavor
`Substance, is delivered to the Smoker. The circuitry also
`preferably prevents the actuation of any particular heater
`more than once, to prevent overheating of the tobacco flavor
`medium thereon and consequent production of undesired
`compounds yielding off tastes.
`In Such an article, the heating elements are disposed of
`along with the spent flavor generating medium. This results
`in increased costs to the Smoker, who must buy new heating
`elements with each refill of tobacco flavor medium. The
`Volume of material disposed of is also greater when the
`heating elements must be disposed of.
`In addition, when the heating elements are disposable,
`they must by their nature be removable. As a result, there is
`Sometimes excessive contact resistance at the connection
`where the removable heaters are electrically connected to
`the Source of electrical energy, resulting in increased power
`consumption. Furthermore, that connection must be
`designed to withstand repeated insertion of new heating
`elements after each use.
`Also, when the heating elements are disposable, the heater
`electrical resistance may vary from heater to heater, result
`ing in variations in power consumption which, in turn, can
`lead to variations in temperature. AS it is the temperature to
`which the tobacco flavor medium is heated that determines
`the characteristics of the flavor tobacco Substance, those
`characteristics will also vary.
`The above-discussed disadvantages associated with U.S.
`Pat. No. 5,060,671 are addressed by above-incorporated
`copending, commonly-assigned U.S. patent application Ser.
`
`25
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`2
`No. 08/012,799, filed Feb. 2, 1993. That application
`describes an electrically-heated Smoking article that has
`reusable heating elements and a disposable portion for
`tobacco flavor generation. The disposable portion preferably
`includes a tobacco flavor Segment and a filter Segment,
`attached by a plug wrap or other fastening means.
`A disadvantage of reusable heating elements is that
`residual aerosol can Settle and condense on the heating
`elements and other permanent Structural components of the
`article, resulting in the generation of undesirable aeroSol
`components if the residual aerosol is reheated after new
`disposable tobacco flavor medium is inserted into the article.
`Such residue is referred to as “fixture contamination.”
`In light of the above, it would therefore be desirable to be
`able to provide an electrically-heated Smoking article in
`which the heating elements are reusable, and of which the
`Volume of disposable portions is thus minimized.
`It would also be desirable to be able to provide such an
`article in which generation of undesirable aerosol compo
`nents resulting from the reheating of aerosol that Settles or
`condenses onto the heating elements and other permanent
`Structural components of the article is minimized.
`It would further be desirable to be able to provide manu
`facturing processes for Such an article that can be imple
`mented using conventional high-volume assembly machin
`ery.
`
`SUMMARY OF THE INVENTION
`It is an object of this invention to provide an electrically
`heated Smoking article in which the heating elements are
`reusable, and of which the Volume of disposable portions is
`thus minimized.
`It is also an object of this invention to provide Such an
`article in which generation of undesirable aerosol compo
`nents as a result of reheating of aeroSol that Settles or
`condenses onto the heating elements and other permanent
`Structural components of the article is minimized.
`It is a further object of this invention to provide manu
`facturing processes for Such an article that can be imple
`mented using conventional high-volume assembly machin
`ery.
`In accordance with this invention, there is provided a
`removable tobacco flavor unit for use in a Smoking article
`for delivering to a Smoker a tobacco flavor Substance, the
`article having a plurality of permanent electrical heating
`means disposed in a permanent cavity. The removable
`tobacco flavor unit includes a carrier having a first end and
`a Second end and having a first Surface and a Second Surface,
`the first Surface defining a flavorant cavity for generating the
`tobacco flavor Substance between Said first end and Said
`Second end, and the Second Surface adapted to be disposed
`adjacent the plurality of electrical heating means. Tobacco
`flavor generating medium is disposed on the first Surface of
`said carrier. When any one of the plurality of electrical
`heating means is activated, a respective fraction of Said
`tobacco flavor medium in thermal transfer relationship with
`Said one of Said heating means is heated, generating a
`predetermined quantity of tobacco flavor Substance for
`delivery to the Smoker. Filtering means for filtering the
`predetermined quantity of tobacco flavor Substance prior to
`Smoking by the Smoker is also provided by the tobacco
`flavor unit.
`A method and apparatus for manufacturing the removable
`tobacco flavor unit are also provided.
`In accordance with the present invention there is also
`provided a permanent heater fixture for use in a Smoking
`
`Philip Morris Products, S.A.
`Exhibit 1022
`Page 015
`
`

`

`5,865,185
`
`3
`article for delivering to a Smoker a tobacco flavor Substance,
`the article having a removable tobacco flavor unit that has
`tobacco flavor medium disposed on a first Surface of a
`carrier, the carrier having a Second Surface opposed to the
`first Surface. The permanent heater fixture includes a heater
`base defining a first end of a cavity for receiving the
`removable tobacco flavor unit, the cavity having an air
`passageway from the first end to a Second end for allowing
`air to pass therebetween. The fixture also includes a plurality
`of permanent electrical heaters disposed on the heater base,
`the heaters each having a Surface adapted to be disposed
`adjacent the Second Surface of the carrier. When any one of
`Said plurality of electrical heating means is activated, a
`respective fraction of Said tobacco flavor medium in thermal
`transfer relationship with Said one of Said heating means is
`heated, generating a predetermined quantity of tobacco
`flavor Substance for delivery to the Smoker.
`The present invention further includes a Smoking article
`for delivering to a Smoker a tobacco flavor Substance. The
`article can include both the permanent heater fixture and the
`removable tobacco flavor unit of the present invention.
`
`4
`FIG. 10 is a longitudinal cross-sectional view of the
`preferred embodiment of a permanent heater unit for the
`“center draw” embodiment of the present invention;
`FIG. 11A is a radial cross-sectional view of the permanent
`heater unit of FIG. 10, taken from line 11A-11A of FIG.10;
`FIG. 11B is a radial cross-sectional view of the permanent
`heater unit of FIG. 10, taken from line 11B-11B of FIG. 10.
`FIG. 12 is a Schematic diagram of a preferred embodiment
`of a control circuit for use in the present invention; and
`FIG. 13 is a schematic diagram of a preferred embodiment
`of the timing network of the control circuit of FIG. 12.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`An electrical Smoking article according to the present
`invention can be used, for example, to simulate a cigarette.
`In Such a case, the tobacco flavor medium would be a
`material containing tobacco or tobacco derivatives. In accor
`dance with the invention, the electrical Smoking article
`would include a removable disposable unit which includes
`the tobacco flavor medium and residual aerosol filters or
`barriers to prevent undesirable deposition of aeroSol con
`densate. The disposable tobacco flavor unit can also include,
`if desired, a free-flow filter for filtering main-Stream aeroSol
`prior to delivery to the Smoker.
`The disposable tobacco flavor unit of the electrical smok
`ing article of the present invention is inserted into a reusable
`"permanent' portion including a Source of electrical energy,
`a set of reusable heating elements, and control circuitry for
`energizing the heaters in an appropriate Sequence, in
`response to manual actuation or puff-induced actuation.
`Preferably, the present invention also includes control cir
`cuitry for delivering a predetermined amount of electrical
`energy to each heater upon actuation, independent of the
`power Supply loaded Voltage. Other Suitable control cir
`cuitry is also described in above-incorporated commonly
`assigned U.S. Pat. No. 5,060,671, which is hereby incorpo
`rated by reference.
`The reusable or permanent portion includes a permanent
`cavity at the mouth end thereof for insertion of the dispos
`able tobacco flavor unit. The reusable heaters are disposed in
`the permanent cavity in Such a way that they are in thermal
`transfer relationship with the disposable tobacco flavor unit
`when the unit is inserted into the permanent cavity. This can
`be accomplished by having the heaters protrude from the
`Sides of the cavity and making the disposable unit partly
`compressible, So that the heaters press into the carrier
`material which Supports the tobacco flavor medium, to be
`discussed below, on the tobacco flavor unit.
`When reusable heaters are used, it is important that
`condensation of aerosol onto power Source components,
`control circuitry, and other permanent Structural portions,
`and particularly the heating elements, of the article be
`minimized. Otherwise, residues from a previous use (i.e.,
`fixture contamination), which might include partially
`oxidized, pyrolized or thermally decomposed constituents of
`the tobacco flavor medium, might be reheated, possibly
`giving rise to undesirable compounds and off tastes being
`delivered to the Smoker. Such residues are not of concern
`when the heaters are disposable, as in above-discussed U.S.
`Pat. No. 5,060,671, because normally they are never
`reheated, but may be of concern where reusable heaters are
`provided, as in the present invention.
`The permanent heaters of the present invention are iso
`lated from the tobacco flavor air passageway and aeroSol
`
`1O
`
`15
`
`25
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`The above and other objects and advantages of the present
`invention will be apparent upon consideration of the fol
`lowing detailed description, taken in conjunction with
`accompanying drawings, in which like reference characters
`refer to like parts throughout, and in which:
`FIG. 1 is a perspective view of an electrical Smoking
`article according to this invention;
`FIG. 2 is a partially fragmentary, exploded perspective
`view of the electrical Smoking article of FIG. 1;
`FIG. 3 is a radial cross-sectional view of the electrical
`Smoking article of FIGS. 1 and 2, taken from line 3-3 of
`FIG. 2;
`FIG. 3A is a radial cross-sectional view of the electrical
`Smoking article of FIGS. 1-3, taken from line 3A-3A of
`FIG. 1;
`FIG. 4 is a longitudinal cross-sectional view of a “center
`draw” embodiment of the electrical smoking article of FIGS.
`1-3A, taken from line 4-4 of FIG. 2;
`FIG. 5 is a partially fragmentary, perspective view of the
`disposable tobacco flavor unit of the electrical Smoking
`article of FIGS. 1-4, taken from line 5–5 of FIG. 2;
`FIG. 6 is a preferred embodiment of apparatus for manu
`facturing the center portion of the disposable tobacco flavor
`unit of the electrical smoking article of FIGS. 1-5;
`FIG. 7 is a longitudinal cross-sectional view similar to
`FIG. 4 but for a “peripheral draw” embodiment of the
`present invention;
`FIG. 8 is a partially fragmentary, perspective view of the
`disposable tobacco flavor unit of the electrical Smoking
`article of FIG. 7;
`FIG. 9A is a radial cross-sectional view of the electrical
`Smoking article of FIGS. 7 and 8, taken from line 9A-9A
`of FIG. 7;
`FIG. 9B is a radial cross-sectional view of the electrical
`smoking article of FIGS. 7 and 8, taken from line 9B-9B
`of FIG. 7;
`FIG. 9C is a radial cross-sectional view of the electrical
`smoking article of FIGS. 7 and 8, taken from line 9B-9B
`of FIG. 7 after the disposable tobacco flavor unit is inserted
`into the permanent heater portion of the electrical Smoking
`article;
`
`Philip Morris Products, S.A.
`Exhibit 1022
`Page 016
`
`

`

`5,865,185
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`15
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`25
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`35
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`40
`
`S
`cavity. This isolation minimizes condensation of aeroSol
`onto the heaters and therefore minimizes aerosol residue
`reheating and undesirable flavor generation. Additionally, a
`back-flow filter is preferably also provided to reduce or
`substantially prevent the back flow of aerosol from the
`tobacco flavor cavity towards the power Source components
`and control circuit. Such back flow of aerosol may give rise
`to the generation of undesirable flavors if the aerosol is able
`to condense onto Surfaces that may be elevated in tempera
`ture.
`Although the permanent heaters of the present invention
`are in thermal transfer relationship with the tobacco flavor
`medium, they are also separated from the tobacco flavor
`material by a carrier which Supports the tobacco flavor
`medium. Such carriers should preferably be able to support
`the tobacco flavor medium when “rolled' into a tube or other
`configuration, as discussed below, should preferably be
`thermally stable so as to be able to withstand the tempera
`tures produced by the permanent heaters, and should pref
`erably also be thermally transmissive to allow the heat
`generated by the permanent heaters to be efficiently trans
`ferred to the tobacco flavor medium. Materials which fulfill
`these characteristics include paper and paper-like materials.
`More preferably, the carrier of the present invention is
`made from a nonwoven carbon fiber mat of the type dis
`closed in copending, commonly-assigned U.S. patent appli
`cation Ser. No. 07/943,747, filed concurrently herewith, and
`incorporated herein by reference in its entirety. Such mats
`should preferably have a thickness between about 0.05 mm
`and about 0.11 mm and be composed of nonwoven carbon
`fibers (having a basis weight in the range of from about 6
`g/m to about 12 g/m with fiber diameters between about 7
`um and about 30 um). The lengths of the fibers should allow
`the mat to withstand the tensile Stresses encountered during
`processing. Preferably, the mats should include a binder
`which is Suitable for use in electrical Smoking articles (i.e.,
`having acceptable Subjective properties).
`Tobacco flavor material which is disposed on the surface
`of the carrier of the present invention can be any material
`that liberates flavors when heated and is able to adhere to the
`Surface of the carrier. Such materials include continuous
`sheets, foams, gels, dried slurries, or dried spray-deposited
`Slurries, which may or may not contain tobacco or tobacco
`derived materials, and which are more fully discussed in the
`above-incorporated U.S. patent application Ser. No. 07/943,
`747. It is desirable that the tobacco flavor material contain
`an aerosol precursor to deliver the tobacco flavor containing
`Substance as an aeroSol, So that when the Smoker exhales the
`tobacco flavor containing Substance, the visible condensed
`aeroSol may mimic the appearance of cigarette Smoke.
`Because the tobacco flavor material of the present inven
`tion is disposed on the Surface of the carrier material, its
`flavor delivery properties can be spatially varied to allow the
`flavor delivery profile from puff to puff to be selectively
`varied. For example, the tobacco flavor material adjacent a
`first heater can contain a first amount or type of flavorant,
`whereas the tobacco flavor material adjacent a Second heater
`can contain a Second different amount or type of flavorant.
`Thus, the flavor delivery to a smoker can be selectively
`varied or tailored by employing nonuniform tobacco flavor
`material profiles disposed on the Surface of the carrier
`material. of course, this particular embodiment may require
`the smoker to orient the disposable unit relative to the
`permanent heaters, when it is inserted into the permanent
`cavity, if it is desired that a particular heater heat a prede
`termined portion of the non-uniform tobacco flavor material.
`Additionally, flavor delivery can also be selectively varied
`in accordance with present invention by providing a con
`
`45
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`50
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`55
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`60
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`65
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`6
`trolled amount of energy to the heaters of present invention.
`For example, if the amount of energy delivered to the first
`heater (e.g., 20 Joules) is greater than the amount delivered
`to the Second (e.g., 15 Joules), then the temperature that the
`first heater will achieve will be greater than that of the
`Second. Therefore, the first heater will generate more aeroSol
`or flavorants than the Second, assuming the temperature is
`not high enough to cause undesirable burning of the tobacco
`flavor material. In this manner the generation of aerosol or
`flavorants can be Selectively controlled by varying the
`amount of energy delivery from puff to puff.
`Furthermore, flavor delivery can also be selectively varied
`in accordance with the present invention by varying the
`amount of energy delivered from disposable tobacco flavor
`unit to disposable tobacco flavor unit. For example, if the
`amount of energy delivered, per puff, to a first disposable
`unit (e.g., 20 Joules/puff) is greater than the amount deliv
`ered to a second (e.g., 15 Joules/puff), then the temperature
`that the first unit will achieve will be greater than that of the
`Second. Therefore, the first unit will generate more aeroSol
`or flavorants per puff than the Second, assuming the tem
`perature is not high enough to cause undesirable burning of
`the tobacco flavor material. In this manner the generation of
`aeroSolor flavorants can be Selectively controlled by varying
`the amount of energy delivery from unit to unit.
`Residual aeroSol which condenses onto the permanent
`heaters of the present invention can be partly removed by the
`wiping action of the inner part of a new tobacco flavor unit
`against the heaters as the new tobacco flavor unit is inserted.
`Thus, the insertion end of the tobacco flavor unit pushes any
`residues on the heater Surfaces toward the ends of the
`heaters. For this reason, the tobacco flavor unit should be
`relatively firm, and the heaters should preferably have a
`Smooth Surface finish to assure that the wiping action is
`effective.
`The parameters of the permanent heaters are chosen to
`allow delivery of an effective amount of tobacco flavor
`Substance-e.g., an aeroSol containing tobacco flavors-to
`the Smoker under Standard conditions of use. For example,
`it may be desirable to deliver 1 to 2 mg of aerosol to a
`Smoker during a 35 ml puff having a two-Second duration.
`It has been found that in order to achieve Such delivery,
`the heaters should be able to reach a temperature of between
`about 200° C. and about 700° C. when in thermal transfer
`relationship with the tobacco flavor medium. Further, the
`heaters should preferably consume between about 5 to 40
`Joules of energy, more preferably about 10–25, and even
`more preferably about 20 Joules.
`Heaters having Such characteristics preferably have an
`active surface area of between about 3 mm and about 20
`mm and preferably have a resistance of between about 0.5
`S2 and about 3.0 G.2. More preferably, the heaters should have
`a resistance of between about 0.8 S2 and 2.1 S2. Of course,
`the heater resistance will also be dictated by the particular
`power Source that is used to provide the necessary electrical
`energy to heat the heaters. For example, the above heater
`resistances correspond to embodiments where power is
`Supplied by four Series-connected nickel-cadmium battery
`cells with a total power Source Voltage of approximately 4.8
`to 5.8 volts, as discussed below. In the alternative, if six or
`eight Such Series-connected batteries are used, the heaters
`should preferably have a resistance of between about 3 and
`5 ohms or between about 5 and 7 ohms, respectively.
`The materials of which the heaters are made are prefer
`ably chosen to assure reliable repeated uses of at least 1,800
`on/off cycles without failure. The heater materials are also
`
`Philip Morris Products, S.A.
`Exhibit 1022
`Page 017
`
`

`

`7
`chosen based on their reactivities, to assure that they will not
`react with the tobacco flavor medium at any temperature
`likely to be encountered to form any undesired compounds.
`Similarly, the heaters themselves should not evolve any
`undesired compounds even when heated out of the presence
`of the tobacco flavor medium. Alternatively, heaters that
`might otherwise evolve undesired compounds could be
`encapsulated in an inert heat-conducting material Such as a
`Suitable ceramic material.
`Based on these criteria, materials for the electric heating
`means of the present invention include carbon, graphite,
`Stainless Steel, tantalum, metal ceramic matrices, and metal
`alloys, Such as iron alloys, and nickel-chromium alloyS.