11(cid:127) 111111111111111
`
`US005665262A
`[111 Patent Number:
`[451 Date of Patent:
`
`5,665,262
`Sep. 9, 1997
`
`United States Patent c191
`llajaligol et al.
`
`[54] TUBULAR HEATER FOR USE IN AN
`ELECTRICAL SMOKING ARTICLE
`
`[75]
`
`Inventors: Mohammad R. Hajaligol, Richmond;
`Grier S. Fleiscbhauer, Midlothian,
`both of Va.; Seetharama C. Deevi, Oak
`Ridge, Tenn.; Charles T. Higgins,
`Richmond; Patrick H. Hayes, Chester,
`both of Va.; Herbert Hennan, Port
`Jefferson; Robert V. Gansert, Lake
`Grove, both of N.Y.; AJfred L Collins,
`Powhatan, Va.; Billy J. Keen, Jr.,
`Chesterli.eld, Va.; Bernard C. Laroy,
`Richmond, Va.; A, Clifton Lilly, Jr.,
`Chesterli.eld, Va.
`
`[73] Assignee: Philip Morris Incorporated, New
`Yor.k,N.Y.
`
`[21] Appl No.: 370,125
`Jan. 9, 1995
`
`[22] Filed:
`
`Re1ated U.S. Application Data
`
`[63] Continuation of Ser. No. 224,848,Apr. 8, 1994, abandoned,
`which is a continuation-in-part of Ser. No. 118,665, Sep. 10,
`1993, Pat. No. 5,388,594, which is a c011.tinuation-in-part af
`Ser. No. 943,504, Sq,. 11, 1992, Pat No. 5,502,214, which
`is a continuatioo-in-part of Ser. No. 666,926, Mar. 11, 1991,
`abandOll.ed.
`Int. CL 6 ................................. HOSB 3/10; A24F 1/22
`[51]
`[52] U.S. CL ........................... 219/553; 219/543; 131/194
`[58] Field of Search -----········ 219/538, 539,
`219/542, 543, 553; 338/283; 3921386; 501/102-105;
`131/194, 195
`
`[56]
`
`References Cited
`
`U.S. PATENT DOCUMENl'S
`
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`
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`
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`OTHER PUBLlCATIONS
`
`Amin, "Arc Spray Coatings Using Inert Gases," TWI Bul(cid:173)
`letin 6, pp. 129-132, Nov./Dec. 1992.
`
`(List continued on next page.)
`
`Primary Examiner-Teresa J. Walberg
`Assistant Examiner-Sam. Paik
`Attom~ Agen~ or Firm-James T. Moore; James E.
`Schardt; Charles E. B. Glenn
`ABSTRACT
`
`[57]
`
`A cylindrical tube is provided of a mechauically strong and
`flexible electrical conductor such as a metal and has a
`plurality of separated regions. An electrically insulating
`layer such as a ceramic is applied on the outer surface except
`for one exposed portion. Electrically resistive heaters are
`then applied to the insulated regions and are electrically
`connected at one end to the underlying electrical conducting
`region. The electrical conductor is connected to the negative
`terminal of a power source. The other end of all the heaters
`are adapted to be connected to the positive terminal of the
`source. Accordingly, an electrically resistive heating circuit
`is formed wherein the tube serves as a common for all of the
`heating elements. The tubular heater can comprise an
`exposed end hub with a plurality of blades extending there(cid:173)
`from. Each blade can have an individual heater deposited
`thereon. Alternatively, every other blade can have a heater
`deposited thereon. The blades having no heater function as
`barriers to minimize outward escape of generated vapors.
`These barrier blades also function as heat sinks for the
`heaters on adjacent blades.
`
`(List continued on next page.)
`
`79 Claims, 15 Drawing Sheets
`
`Ex. 2009-0001
`
`

`

`5,665,262
`~age 2
`
`U.S. PJJENT DOCUMENTS
`
`2,971,039
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`4,193,411
`4,215,708
`4,219,032
`4,246,913
`4,256,945
`4,259,970
`4,303,083
`4,319,591
`4,393,884
`4,431,903
`4,436,100
`4,463,247
`4,503,319
`4,505,282
`4,507,394
`4,562,337
`4,570,646
`4,580,583
`4,621,649
`4,623,401
`4,637,407
`4,659,680
`4,659,912
`4,732,168
`4,735,217
`4,771,796
`4,776,353
`4,788,0TT
`4,837,421
`4,846,199
`4,848,376
`4,874,924
`4,877,989
`4,891,343
`4,922,901
`4,945,931
`4,947,874
`4,947,875
`4,966,171
`4,981,522
`4,991,606
`5,040,552
`5,060,671
`5,076),96
`5,093,894
`5,095,921
`5,144,962
`5,157,242
`5,159,940
`5),24,498
`5),35,157
`5,249,586
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`8/1993 Blackbum ............................... 219,268
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`
`5,274,214 12/1993 Blackbum .............. __ _ 219fl68
`5,285,050
`2/1994 Blackbum ............................... 219fl68
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`5,322,075
`5,353,813 10/1994 Deevi et al ..
`5,369,723 11/1994 Counts et al ..
`2/1995 Counts et al ..
`5,388,594
`
`FOREIGN PJJENT DOCUMENTS
`
`0503 767 Al
`3640 917
`37 35 704
`61-68061
`64-17386
`2132 539
`2148 079
`2148 676
`86/02528
`WO 94/06314
`
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`5/1989 Germany.
`4/1986
`Japan .
`1/1989 Japan.
`7/1984 United Kingdom.
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`5/1985 United Kingdom.
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`3/1994 WIPO .
`
`OTHER PUBLICATIONS
`
`Blunt et al, "High Velocity Spraying for Electronic Sub(cid:173)
`strates," TWI Connect-World Centre for Materials Joining
`Technology, No. 40, Dec. 1992.
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`Ceramic," Ceramic Bulletin, vol 69, No. 12, pp.
`1955-1958, 1990.
`Herman, "Coatings and Coating Practices," Advanced Mate(cid:173)
`rials & Pro,::esses, pp. 59-60, 84-85, Jan. 1990.
`Herman, "Plasma-Sprayed Coatings," Scientific American,
`pp. 112-116, 1988.
`Herman, ''Plasma Spray Deposition Processes," MRS Bul(cid:173)
`letin, pp. 60-67, 1988.
`Sampath et al, ''Microstructure and Properties of Plas(cid:173)
`ma-Spray Consolidated/I'wo-Phase Nickel Aluminides,"
`vol. 25, pp. 1425-1430, 1991.
`Sampath et al, "Structure and Properties of Vacuum Plasma
`Sprayed Hard Coatings;' Memories et Etudes Scientifiques
`Revue de Metallurgie, pp. 289-294, Mai 1991.
`Srivatsan et al, "Review Use of Spray Techniques to Syn(cid:173)
`thesize Particulate-Reinforced Metal-Matrix Composites,"
`Journal of Materials Science 27, pp. 5965-5981, 1992.
`Street et al, 'Trends In Laser Cutting of Advanced Materi(cid:173)
`als," TWI Bulletin 5, pp. 108-111, SepJOct. 1992.
`Tiwari et al, Spray Forming of MoSi2 and MoSi;i-Based
`Composites, Mat. Res, Soc. Symp. Proc., vol. 213, Materials
`Research Society, pp. 807-813, 1991.
`'Iiwari et al, 'Thermal Spray Forming of Particulate Com(cid:173)
`posites," Dept. of Mat Sci. & Engineering, State University
`of New York, Stony Brook, NY 11794-2275 and Flame
`Spray Industries, Inc., 152 Haven Avenue, Port Washington,
`NY 11050.
`Tiwari et al, "Incoxporating of Reinforcements in Spray
`Formed MMCs", Department of Materials Science and
`Engineering, State University of New York, Stony Brook,
`NY 11794-2275.
`'Iravis, ''Making Materials That Are Good to the Last Drop,"
`Research News, vol. 258, p. 1307, Nov. 1992.
`Wang et al, "Activation Energy for Crystal Growth Using
`Isothermal and Continuous Heating Processes", Journal of
`Materials Science, Chapman and Hall, vol. 25, pp.
`2339-2343, 1990.
`Wang et al,
`'Thermomechanical Properties of Plas(cid:173)
`ma-Sprayed Oxides in the Mg0-A12O3-SiO2 system," Sur(cid:173)
`face and Coatings Technology, vol. 42, pp. 203-216, 1990.
`Wu et al, "Heat Transfer to a Particle in a Thermal Plasma,"
`Trans IChemE, vol 69, Part A, pp. 21-24, Jan. 1991.
`
`Ex. 2009-0002
`
`

`

`5,665,262
`Page3
`
`bat, "A Quarter of a Century of Plasma Spraying," Ann.
`Rev. Mater. Sci.by Annual Reviews, Inc., pp. 13 :9-42, 1983.
`Zatorski et al, "Wear of Plasma-Sprayed Alumina-Titania
`Coatings," High Performance Ceramic Films and Coatings
`by Elsevier Science Publishers B.V., pp., 591-601, 1991.
`Fen et al., "Cyclic oxidation of Haynes 230 alloy," Chapman
`& Hall, pp. 1514-1520 (1992).
`Reinshagen and Sikka, 'Thermal Spraying of Selected Alu(cid:173)
`minides," Proceedings of the Fourth National Thermal
`Spray Conference, Pittsburgh, PA USA, pp. 307-313 ( 4-10
`May 1991).
`Kutner, 'Thermal spray by design," Reprint from Advanced
`Materials & Processes Incorporating Metal Progress, Oct
`(1988).
`
`"Characterizing Thermal Spray Coatings," Article based on
`presentations made at the Fourth National Thermal Spray
`Conference, 4-10 May (1991) and appearing in Advanced
`Materials and Processes, May 1992, pp. 23-27.
`Howes, Jr., "Computerized Plasma Control for Applying
`Medical-Quality Coatings," Industrial Heating, pp. 22-25,
`Aug., 1993.
`V. Si.kka, "Processing of Intermetallic Aluminides", Inter(cid:173)
`metallic Metallurgy and Processing Intermetallic Com(cid:173)
`pounds, ed. Stoloff et al., Van Mestrand Reinhold, N.Y.,
`1994.
`.
`Excerpt from "NASA Tech Briefs," JulJAug. 1988, p. 31.
`"PCT Thermistors," Keystone Carbon Company product
`literature.
`
`Ex. 2009-0003
`
`

`

`U.S. Patent
`US. Patent
`
`Sep. 9, 1997
`Sep. 9, 1997
`
`Sheet 1 of 15
`Sheet 1 of 15
`
`5,665,262
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`Ex. 2009-0004
`
`Ex. 2009-0004
`
`

`

`U.S. Patent
`
`Sep. 9, 1997
`
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`5,665,262
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`

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`U.S. Patent
`US. Patent
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`Sep. 9, 1997
`Sep. 9, 1997
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`Sheet 3 of 15
`Sheet 3 of 15
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`

`

`U.S. Patent
`US. Patent
`
`Sep.9,1997
`Sep. 9, 1997
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`

`

`U.S. Patent
`US. Patent
`
`Sep. 9, 1997
`Sep. 9, 1997
`
`Sheet 5 of 15
`Sheet 5 of 15
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`Ex. 2009-0008
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`

`

`U.S. Patent
`US. Patent
`
`Sep. 9, 1997
`Sep. 9, 1997
`
`Sheet 6 of 15
`Sheet 6 of 15
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`5,665,262
`5,665,262
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`
`Ex. 2009-0009
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`Ex. 2009-0009
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`

`

`U.S. Patent
`US. Patent
`
`Sep. 9, 1997
`Sep. 9, 1997
`
`Sheet 7 of 15
`Sheet 7 of 15
`
`5,665,262
`5,665,262
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`
`Ex. 2009-0010
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`Ex. 2009-0010
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`

`

`US. Patent
`U.S. Patent
`
`Sep.9, 1997
`Sep. 9, 1997
`
`Sheet 8 of 15
`Sheet 8 of 15
`
`5,665,262
`5,665,262
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`
`Ex. 2009-0011
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`Ex. 2009-0011
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`

`U.S. Patent
`US. Patent
`
`Sep.9, 1997
`Sep. 9, 1997
`
`Sheet 9 of 15
`Sheet 9 of 15
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`5,665,262
`5,665,262
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`Ex. 2009-0012
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`Ex. 2009-0012
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`

`U.S. Patent
`US. Patent
`
`Sep.9, 1997
`Sep. 9, 1997
`
`Sheet 10 of 15
`Sheet 10 of 15
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`5,665,262
`5,665,262
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`Ex. 2009-0013
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`Ex. 2009-0013
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`U.S. Patent
`US. Patent
`
`Sep.9,1997
`Sep. 9, 1997
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`U.S. Patent
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`Sep. 9, 1997
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`U.S. Patent
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`Sep. 9, 1997
`Sep. 9, 1997
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`

`

`U.S. Patent
`
`Sep. 9, 1997
`
`Sheet 15 of 15
`
`5,665,262
`
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`
`Ex. 2009-0018
`
`

`

`5,665,262
`
`1
`TUBULAR HEATER FOR USE IN AN
`ELECTRICAL SMOKING ARTICLE
`
`CROSS REFERENCE TO REl..iITED
`APPLICATIONS
`
`The present application is commonly assigned patent
`application Ser. No. 08/224,848, filed Apr. 8, 1994, aban(cid:173)
`doned which is a continuation-in-part of patent application
`Ser. No. 08/118,665, filed Sep. 10, 1993, U.S. Pat. No.
`5,388,594, which in turn is a continuation-in-part of com(cid:173)
`monly assigned patent application Ser. No. 07/943,504, filed
`Sep. 11, 1992, U.S. Pat. No. 5,502,214, which in turn is a
`continuation-in-part of patent application Ser. No. 07/666,
`926 filed Mar. 11, 1991, now abandoned in favor of file(cid:173)
`wrapper continuation application Ser. No. 08/012,799, filed
`Feb. 2, 1993, which is now U.S. Pat. No. 5,249,586, issued
`Oct. 5, 1993. The present application relates to commonly
`assigned copending U.S. patent applications Ser. No.
`08/365,952 filed Dec. 29, 1994 (Attorney Docket No. PM
`1767), Ser. No. 07/943,747, filed Sep. 11, 1992 and to
`commonly assigned U.S. Pat No. 5,060,671, issued Oct. 29,
`1991; U.S. Pat No. 5,095,921, issued Mar. 17, 1992; and
`U.S. Pat. No. 5,224,498, issued Jul. 6, 1992. All of these
`referenced and related patents and applications, are hereby
`incorporated by reference.
`
`BACKGROUND OF THE INVENTION
`
`1. Technical Field of the Invention
`The present invention relates generally to heaters for use
`in an electrical smoking article and more particularly to a
`tubular heater for use in an electrical smoking article.
`2._Discussion of the Related Art
`Previously known conventional smoking devices deliver
`flavor and aroma to the user as a result of combustion of
`tobacco. A mass of combustible material, primarily tobacco,
`is oxidized as the result of applied, heat with typical com(cid:173)
`bustion temperatures in a conventional cigarette being in
`excess of 800° C. during puffing. Heat is drawn through an
`adjacent mass of tobacco by drawing on the mouth end.
`During this heating, inefficient oxidation of the combustible
`material takes place and yields various distillation and
`pyrolysis products. As these products are drawn through the
`body of the smoking device toward the mouth of the user,
`they cool and condense to form an aerosol or vapor which
`gives the consumer the flavor and aroma associated with
`smoking.
`Conventional cigarettes have various perceived draw(cid:173)
`backs associated with them. Among them is the production
`of sidestream smoke during smoldering between puffs,
`which may be objectionable to some non-smokers. Also,
`once lit, they must be fully consumed or be discarded.
`Relighting a conventional cigarette is possible but is usually
`an unattractive prospect for subjective reasons (flavor, taste,
`odor) to a discerning smoker.
`A prior alternative to the more conventional cigarettes
`include those in which the combustible material itself does
`not directly provide the flavorants to the aerosol inhaled by
`the smoker. In these smoking articles, a combustible heating
`element, typically carbonaceous in nature, is combusted to
`heat air as it is drawn over the heating-element and through
`a zone which contains heat-activated elements that release a
`flavored aerosol. While this type of smoking device pro(cid:173)
`duces little or no sidestream smoke, it still generates
`products, of combustion, and once lit it is not adapted to be
`snuffed for future use in the conventional sense.
`
`5
`
`25
`
`2
`In both the more conventional and carbon element heated
`smoking devices described above combustion takes place
`during their use. This process naturally gives rise to many
`by-products as the combusted material breaks down and
`interacts with the surrounding atmosphere.
`Commonly assigned U.S. Pat. Nos. 5,093,894; 5,225,498;
`5,060,671 and 5,095,921 disclose various electrical resistive
`heating elements and flavor generating articles which sig(cid:173)
`nificantly reduce sidestream smoke while permitting the
`10 smoker to selectively suspend and reinitiate smoking.
`However, the cigarette articles disclosed in these patents are
`not very durable and may collapse, tear or break from
`extended or heavy handling. In certain circumstances, these
`prior cigarette articles, may crush as they are inserted into
`15 the electric lighters. Once they are smoked, they are even
`weaker and :may tear or break as they are removed from the
`lighter.
`U.S. patent application Ser. No. 08/118,665, filed Sep. 10,
`1993, describes an electrical smoking system including a
`20 novel electrically powered lighter and novel cigarette that is
`adapted to cooperate-with the lighter. The preferred embodi(cid:173)
`ment of the lighter includes a plurality of metallic sinusoidal
`heaters disposed in a configuration that slidingly receives a
`tobacco rod portion of the cigarette.
`The preferred embodiment of the cigarette of Ser. No.
`08/118,665 preferably comprises a tobacco-laden tubular
`carrier, cigarette paper overwrapped about the tubular
`carrier, an arrangement of flow-through filter plugs at a
`30 mouthpiece end of the carrier and a filter plug at the opposite
`(distal) end of the carrier, which preferably limits air flow
`axially through the cigarette. The cigarette and the lighter
`are configured such that when the cigarette is inserted into
`the lighter and as individual heaters are activated for each
`35 puff, localized charring occurs at spots about the cigarette in
`the locality where each heater was bearing against the
`cigarette. Once all the heaters have been activated, these
`charred spots are closely spaced from one another and
`encircle a central portion of the carrier portion of the
`4-0 cigarette. Depending on the maximum temperatures and
`total energies delivered at the heaters, the charred spots
`manifest more than mere discolorations of the cigarette
`paper. In most applications, the charring will create at least
`minute breaks in the cigarette paper and the underlying
`45 carrier material, which breaks tends to mechanically weaken
`the cigarette. For the cigarette to be withdrawn from the
`lighter, the charred spots must be at least partially slid past
`the heaters. In aggravated circumstances, such as when the
`cigarette is wet or toyed with or twisted, the cigarette may
`50 be prone to break or leave pieces upon its, withdrawal from
`the lighter. Pieces left in the lighter fixture can interfere with
`the proper operation of the lighter and/or deliver an off-taste
`to the smoke of the next cigarette. If the cigarette breaks in
`two while being withdrawn, the smoker may be faced not
`55 only with the frustration of failed cigarette product, but also
`with the prospect of clearing debris from a clogged lighter
`before he or she can enjoy another cigarette.
`The preferred embodiment of the cigarette of Ser. No.
`08/118,665 is essentially a hollow tube between the filter
`60 plugs at the mouthpiece end of the cigarette and the plug at
`the distal end. This construction is believed to elevate
`delivery to the smoker by providing sufficient space into
`which aerosol can evolve off the carrier with minimal
`impingement and condensation of the aerosol on any nearby
`65 surfaces.
`Several proposals have been advanced which significantly
`reduce undesired sidestream smoke while permitting the
`
`Ex. 2009-0019
`
`

`

`5,665,262
`
`3
`smoker to suspend smoking of the article for a desired period
`and then to resume smoking. For example, commonly
`assigned U.S. Pat Nos. 5,093,894; 5,225,498; 5,060,671
`and 5,095,921 disclose various heating elements and flavor
`generating articles Parent application Ser. No. 08,118,665 5
`discloses an electrical smoking article having heaters which
`are-actuated upon sensing of a draw by control and logic
`circuitry. The heaters are preferably a relatively thin seipen(cid:173)
`tine structure to transfer adequate amounts of heat to the
`cigarette and is lightweight.
`Although these devices and heaters overcome the
`observed problems and achieve the stated objectives, many
`embodiments are plagued by the formation of a significant
`amount of condensation formed as the tobacco flavor
`medium is heated to form vapors. These vapors can cause 15
`problems as they condense on relatively cooler various
`electrical contacts and the associated control and logic
`circuitry. In addition, condensation can influence the sub(cid:173)
`jective flavor of the tobacco medium of the cigarette.
`Though not desiring to be bound by theory, it is believed that 20
`the condensation is the result of the flow pattern and pressure
`gradient of ambient air drawn through the article and the
`current designs of the heater assemblies. The heating of the
`tobacco flavor medium releases vapors which are then
`cooled to result in condensation on the surfaces of relatively 25
`cooler components. The condensation can cause shorting
`and other undesired malfunctions.
`In addition, the proposed heaters are subject to mechani(cid:173)
`cal weakening and possible failure due to stresses induced
`by inserting and removing the cylindrical tobacco medium
`and also by adjusting or toying with the inserted cigarette.
`Also, the electrical smoking articles employ electrically
`resistive heaters which have necessitated relatively complex
`electrical collllections which can be disturbed by insertion 35
`and removal of the cigarette.
`
`4
`It is another object of the present invention to accomplish
`the foregoing objects simply and in a straightforward man(cid:173)
`ner.
`Additional objects and advantages of the present inven(cid:173)
`tion are apparent from the drawings and specification which
`follow.
`
`SUMMARY OF THE INVENTION
`
`The foregoing and additional objects are obtained by a
`10 heater according to the present invention. A cylindrical tube
`is provided of a mechanically strong and flexible electrical
`conductor such as a metal and has a plurality of separated
`regions. An electrically insulating layer such as a ceramic is
`applied on the outer surface except for one exposed portion.
`Electrically resistive materials are then applied to the insu(cid:173)
`lated regions and are electrically connected at one end to the
`underlying electrical conducting region to form heater ele(cid:173)
`ments. This electrical conducting region is collllected to the
`negative terminal of a power source. The other end of all the
`heaters are adapted to be collllected to the positive terminal
`of the source. Accordingly, an electrically resistive heating
`circuit is formed wherein the tube serves as a common for
`all of the heating elements.
`The tubular heater can comprise an exposed end hub with
`a plurality of blades extending therefrom. Each blade can
`have an individual heater deposited thereon. Alternatively,
`every other blade can have a heater deposited thereon. The
`blades having no heater function as barriers to minimize
`30 outward escape of generated vapors. These barrier blades
`also function as heat sinks for the heaters on adjacent blades.
`
`OBJECTS OF THE INVENTION
`
`It is accordingly an object of the present invention to
`provide a heater which generates smoke from a tobacco 4-0
`medium without sustained combustion.
`It is another object of the present invention to provide a
`heater for a smoking article which reduces the creation of
`undesired sidestream smoke.
`It is yet another object of the present invention to provide
`a heater for a smoking article which permits the smoker to
`suspend and resume use.
`It is a further object of the present invention to accomplish
`the foregoing objects while reducing aerosol or smoke
`condensation within the smoking article.
`It is yet another object of the present invention to provide
`a heater structure which provides a desired number of puffs
`and which is straightforwardly modified to change the
`number and or duration of puffs provided without sacrificing
`subjective qualities of the tobacco.
`It is another object of the present invention to provide a
`method of making such a heater to accomplish the foregoing
`objects.
`It is a further object of the present invention to provide a 60
`heating element for a smoking article which is mechanically
`suitable for insertion and removal of a cigarette.
`It is another object of the present invention to simplify
`connections of an electrically resistive heater to an associ(cid:173)
`ated power source.
`It is a further object of the present invention to provide
`such a heater which is more economical to manufacture.
`
`55
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`FIG. 1 is a partially exposed perspective view of a
`smoking article employing a heater according to the present
`invention;
`FIG. 2 is a side, cross-sectional view of a cigarette used
`in conjunction with the present invention;
`FIG. 3 is a side, cross-sectional view of a heater fixture
`according to the present invention;
`FIG. 4 is an exposed side view of a tubular heater
`according to the present invention;
`FIG. 5 is an exposed side view of a heater blade having
`45 a metal substrate;
`FIG. 6A is a perspective view of dual hubs having a
`plurality of alternating barrier and heater blades extending
`therebetween;
`FIG. 6B is an embodiment similar to that of FIG. 6A
`50 except that the gaps between blades are shaped as an
`elongated U;
`FIG. 7 is a perspective view of the embodiment depicted
`in FIG. 6A having heater elements deposited on every
`defined blade;
`FIG. 8 is a perspective view of a heater having a single
`supporting hub;
`FIG. 9 is a perspective view of tubular heater having
`spiralled, gaps;
`FIG. 10 is an exposed side view of a tubular heater having
`heater elements on inner faces of heater blades;
`FIG. 11 is a perspective view of an arrangement of heater
`blades prior to rolling;
`FIG. 12 is a perspective of view of a tubular heater having
`65 a common blade;
`FIG. 13 is a top view of an arrangement of heater blades
`prior to folding; and
`
`Ex. 2009-0020
`
`

`

`5,665,262
`
`5
`FIG. 14 is a perspective view of another arrangement of
`a tubular heater.
`
`DEI'All.ED DESCRIPITON OF THE
`PREFERRED EMBODIMENTS
`
`5
`
`10
`
`A smoking system 21 according to the present invention
`is generally seen with reference to FIGS. 1 and 2. The
`smoking system 21 includes a cylindrical aerosol generating
`tube or cigarette 23 and a reusable lighter 25. The cigarette
`23 is adapted to be inserted in and removed from an orifice
`'1:1 at a front end 29 of the lighter 25. The smoking system
`21 is used in much the same fashion as a conventional
`cigarette. The cigarette 23 is disposed of after one or more
`puff cycles. The lighter 25 is preferably disposed of after a
`greater number of puff cycles than the cigarette 23.
`The lighter 25 includes a housing 31 and has front and
`rear portions 33 and 35. A power source 37 for supplying
`energy to heating elements for heating the cigarette 23 is
`preferably disposed in the rear portion 35 of the lighter 25.
`The rear portion 35 is preferably adapted to be easily opened
`and closed, such as with screws or with snap-fit components,
`to facilitate replacement of the power source 37. The front
`portion 33 preferably houses heating elements and circuitry
`in electrical communication with the power source 37 in the
`rear portion 35. The front portion 33 is preferably easily
`joined to the rear portion 35, such as with a dovetail joint or
`by a socket fit. The housing 31 is preferably made from a
`hard, heat-resistant material. Preferred materials include
`metal-based or, more preferably, polymer-based materials. 30
`The housing 31 is preferably adapted to fit comfortably in
`the hand of a smoker and, in a presently preferred
`embodiment, has overall dimensions of 10.7 cm by 3.8 cm
`by 1.5 cm.
`The power source 37 is sized to provide sufficient power 35
`for heating elements that heat the cigarette 23. The power
`source 37 is preferably replaceable and rechargeable and
`may include devices such as a capacitor, or more preferably,
`a battery. In a presently preferred embodiment, the power
`source is a replaceable, rechargeable battery such as four 40
`nickel cadmium battery cells connected in series with a total,
`non-loaded voltage of approxiniately 4.8 to 5.6 volts. The
`characteristics required of the power source 37 are, however,
`selected in view of the characteristics of other components
`in the smoking system 21, particularly the characteristics of 45
`the heating elements. U.S. Pat. No. 5,144,962 describes
`several forms of power sources useful in connection with the
`smoking system of the present invention, such as recharge(cid:173)
`able battery sources and quick-discharging capacitor power
`sources that-are charged by batteries, and is hereby incot- 50
`porated by reference.
`A substantially cylindrical heating fixture 39 for heating
`the cigarette 23, and, preferably, for holding the cigarette in
`place relative to the lighter 25, and electrical control cir(cid:173)
`cuitry 41 for delivering a predetermined amount of energy 55
`from the power source 37 to heating elements (not seen in
`FIGS. 1 and 2) of the heating fixture are preferably disposed
`in the front 33 of the lighter. As described in greater detail
`below, a generally circular, terminal end hub 110 is fixed,
`e.g., welded, to be disposed within the interior of heater 60
`fixture 39, e.g., is fixed to spacer 49, as shown in FIG. 3. If
`the heater has two end hubs, either hub can serve as the fixed
`terminal end. In the presently preferred embodiment, the
`heating fixture 39 includes a plurality of radially spaced
`heating elements 122 supported to extend from the hub, seen 65
`in FIG. 3 and described in greater detail below, that are
`individually energized by the power source 37 under the
`
`6
`control of the circuitry 41 to heat a number of, e.g., eight,
`areas around the periphery of the inserted cigarette 23. Eight
`heating elements 122 are preferred to develop eight puffs as
`in a conventional cigarette and eight heater elements also
`lend themselves to electrical control with binary devices. A
`desired number of puffs can be generated, e.g., any number
`between 5-16, and preferably 6-10 or 8 per inserted ciga(cid:173)
`rette. As discussed below, the number of heaters can exceed
`the desired number of puffs/cigarette.
`The circuitry 41 is preferably activated by a puff-actuated
`sensor 45, seen in FIG. 1, that is sensitive either to pressure
`drops that occur when a smoker draws on the cigarette 23.
`The puff-actuated sensor 45 is preferably disposed in the
`front 33 of the lighter 25 and communicates with a space
`15 inside the heater fixture 39 and near the cigarette 23 through
`a passageway extending through a spacer and a base of the
`heater fixture and, if desired, a puff sensor tube (not shown).
`A puff-actuated sensor 45 suitable for use in the smoking
`system 21 is described in U.S. Pat. No. 5,060,671, the
`20 disclosure of which is incorporated by re