United States Patent [19J
`Collins et al.
`
`[54] FIAVOR GENERATING ARTICLE
`
`[75]
`
`Inventors: Alfred L. Collins, Powhatan; Mary
`Ellen Counts, Richmond; Amitabh
`Das, Midlothian; Seetharama C. Deevi,
`Midlothian; Grier S. Fleischhauer,
`Midlothian; Charles T. Higgins; Willie
`G. Houck, Jr., both of Richmond; Billy
`J. Keen, Jr., Chesterfield; Robert E.
`Lee, Ill, Richmond; A. Clifton Lilly,
`Jr., Chesterfield; D. Bruce Losee, Jr.,
`Richmond; Hugh J. McCafferty;
`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,
`Chesterfield; Francis V. Utsch,
`Midlothian, all of Va.
`
`[73] Assignee: Philip Morris Incorporated, New
`York, N.Y.
`
`[ *] Notice:
`
`The portion of the term of this patent
`subsequent to Sep. 10, 2013, has been
`disclaimed.
`
`[21] Appl. No.: 448,906
`May 24, 1995
`[22]
`Filed:
`
`[60]
`
`[51]
`[52]
`
`[58]
`
`[56]
`
`Related U.S. Application Data
`
`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.
`
`........................................................ A24F 1/00
`Int. Cl.6
`U.S. Cl . .......................... 131/194; 131/271; 131/329;
`128/200.14; 128/202.21; 128/203.27
`Field of Search ..................................... 131/194, 329,
`131/271; 128/202.21, 203.27, 200.14
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`I 1111111111111111 111111111111111 1111111111 1111111111 11111 lll111111111111111
`US005865185A
`[11] Patent Number:
`[45] Date of Patent:
`
`5,865,185
`*Feb.2, 1999
`
`1,968,509
`2,057,353
`2,104,266
`2,442,004
`2,974,669
`
`7/1934 Tiffany ...................................... 219/38
`10/1936 Whittemore, Jr. ........................ 219/38
`1/1938 McCormick .............................. 131/12
`5/1948 Hayward-Butt ......................... 128/200
`3/1961 Ellis ........................................ 131/172
`
`(List continued on next page.)
`
`FOREIGN PATENT DOCUMENTS
`
`1202378
`87/104459
`0 295 122
`0 358 002
`0 358 114
`0 430 566A2
`0 438 862A2
`3 640 917
`3 735 704
`61-68061
`2 132 539
`2 148 079
`2 148 676
`WO 86/02528
`WO 95/05094
`
`3/1986
`2/1988
`12/1988
`3/1990
`3/1990
`6/1991
`7/1991
`8/1988
`5/1989
`4/1986
`7/1984
`5/1985
`5/1985
`5/1986
`2/1995
`
`Canada ............................ B23K 3/02
`China.
`European Pat. Off ......... A24F 47/00
`European Pat. Off ......... A24F 47/00
`European Pat. Off. .. ..... A61M 15/00
`European Pat. Off ......... A24F 47/00
`European Pat. Off ......... A24F 47/00
`Germany ....................... A45D 34/02
`Germany ......................... A61L 9/03
`Japan ............................ A61M 15/06
`United Kingdom ............. B23K 3/02
`United Kingdom ............. B23K 3/02
`United Kingdom ............. H05B 3/28
`WIPO ............................ A24B 15/18
`WIPO ............................. A24F 47/00
`
`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 article is provided in which a replaceable tobacco
`flavor unit containing tobacco flavor material is electrically
`heated by 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
`sequentially to the smoker. The replaceable tobacco flavor
`unit can also include a filter to reduce the effect of residual
`aerosol which settles or condenses on the permanent por(cid:173)
`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.
`
`1,771,336
`
`7/1930 Wyss et al. .
`
`75 Claims, 12 Drawing Sheets
`
`---54-----'
`12
`41
`47
`:40
`
`21
`f
`
`43
`I
`- -
`- - ·---- ---
`:-:..-------
`--}=-~.:-__ :
`
`37
`I
`
`--
`
`~
`
`\.
`
`-_ T
`J_
`
`53
`
`- ~ -
`\45
`
`31
`
`43
`
`7 40
`
`Ex. 2018-0001
`
`

`

`5,865,185
`Page 2
`
`U.S. PATENT DOCUMENTS
`
`3,200,819
`3,255,760
`3,363,633
`3,402,723
`3,482,580
`3,496,336
`3,591,753
`3,608,560
`3,738,374
`3,744,496
`3,804,100
`3,889,690
`4,016,061
`4,068,672
`4,077,784
`4,131,119
`4,141,369
`4,164,230
`4,193,411
`4,194,108
`4,203,025
`4,215,708
`4,219,032
`4,246,913
`4,256,945
`4,259,564
`4,259,970
`4,303,083
`4,319,591
`4,393,884
`4,431,903
`4,436,100
`4,463,247
`4,505,282
`4,562,337
`4,570,646
`4,580,583
`4,621,649
`4,623,401
`4,629,604
`
`8/1965 Gilbert .................................... 128/208
`6/1966 Selke ........................................... 131/8
`1/1968 Weber ..................................... 131/178
`9/1968 Hu ........................................... 131/185
`12/1969 Hollebaugh ............................. 131/178
`2/1970 Hingorany et al. ..................... 219/464
`7/1971 Gartner ................................... 219/464
`9 /1971 Briskin .. ... ... ... ....... ... ... ...... .... ... ... 131/2
`6/1973 Bennett ....................................... 131/2
`7/1973 McCarty et al. ............................ 131/8
`4/1974 Fariello ................................... 131/173
`6/1975 Guarnieri ................................ 131/185
`4/1977 Wasa et al. ............................. 204/192
`1/1978 Guerra .. ... ... ... ....... ... ... ...... .... .. 131/1 70
`3/1978 Vayrynen .................................. 55/146
`12/1978 Blasutti ................................... 131/187
`2/1979 Buurruss .. ...... ....... ... ... ...... .... .. 131/1 71
`8/1979 Pearlman . ... ... ....... ... ... ...... .... .. 131/1 71
`3/1980 Faris et al. .............................. 131/171
`3/1980 Nakajima et al. ...................... 219/216
`5/1980 Nakatani et al. ....................... 219/216
`8/1980 Bron ........................................ 131/262
`8/1980 Tabatznik et al. ...................... 131/170
`1/1981 Ogden et al. ........................... 131n71
`3/1981 Carter et al. ......................... 219/10.75
`3/1981 Ohkubo ................................... 219/216
`4/1981 Green, Jr ................................. 131/330
`12/1981 Burruss, Jr. .. .... ... ... ...... ... .... ... . 131/271
`3/1982 Keith et al. ............................. 131/359
`7/1983 Jacobs ..................................... 131/273
`2/1984 Riccio ..................................... 219/238
`3/1984 Green, Jr ................................. 131/330
`7/1984 Lawrence et al. ...................... 219/236
`3/1985 Cogbill et al. .......................... 131/334
`12/1985 Lawrence ................................ 219/421
`2/1986 Herron .................................... 131/185
`4/1986 Green, Jr ................................. 131/330
`11/1986 Osterrath ................................. 131/185
`11/1986 Derbyshire et al. ...................... 148/13
`12/1986 Spector ................................... 422/124
`
`4,637,407
`4,659,912
`4,682,010
`4,686,353
`4,692,590
`4,694,824
`4,735,217
`4,771,796
`4,776,353
`4,837,421
`4,846,199
`4,848,376
`4,874,924
`4,877,989
`4,922,901
`4,945,931
`4,947,874
`4,947,875
`4,966,171
`4,981,522
`4,991,606
`4,998,541
`5,016,656
`5,040,552
`5,042,510
`5,060,671
`5,076,296
`5,093,894
`5,095,921
`5,144,962
`5,159,940
`5,179,966
`5,188,130
`5,224,498
`5,235,157
`5,249,586
`5,269,327
`5,274,214
`5,285,050
`5,388,594
`5,479,948
`
`1/1987
`4/1987
`7/1987
`8/1987
`9/1987
`9/1987
`4/1988
`9/1988
`10/1988
`6/1989
`7/1989
`7/1989
`10/1989
`10/1989
`5/1990
`8/1990
`8/1990
`8/1990
`10/1990
`1/1991
`2/1991
`3/1991
`5/1991
`8/1991
`8/1991
`10/1991
`12/1991
`3/1992
`3/1992
`9/1992
`11/1992
`1/1993
`2/1993
`7/1993
`8/1993
`10/1993
`12/1993
`12/1993
`2/1994
`2/1995
`1/1996
`
`....................... 131/175
`Bonnano et al.
`Derbyshire .............................. 219/535
`Drapeau et al. ........................ 219/381
`Spector ................................... 219/275
`Spector ................................... 219/275
`Ruderian ................................. 128/203
`Gerth et al. ...... ... .... ... ... ...... .... 131/273
`Myer et al. ............................. 131/273
`Lilja et al. .............................. 131/297
`Luthy ...................................... 219/272
`Rose ........................................ 131/329
`Lilja et al. .............................. 131/352
`Yamamoto et al.
`. ................... 219/274
`Drews et al. ........................... 310/323
`Brooks et al. ..................... 128/203.26
`Gori .. ... .... ...... ... ... ....... ... ... ... ... 131/335
`Brooks et al. .......................... 131/329
`Brooks et al. ... ... .... ... ... ... ... .... 131/330
`Seranno et al. .. ... .... ... ... ...... .... 131/194
`Nichols et al. ......................... 131/274
`Serrano et al. . ........................ 131/359
`Perfetti et al. ... ... .... ... ... ...... ... . 131/336
`McMurtrie .............................. 131/364
`Schleich et al. ........................ 131/359
`Curtiss et al.
`... ... .... ... ... ... ... .... 131/273
`Counts et al.
`.......................... 131/329
`Nystrom et al. ........................ 131/359
`Deevi ...................................... 392/390
`Losee et al ............................. 131/194
`Counts et al.
`.......................... 131/194
`Hayward et al. ....................... 131/194
`Losee et al ............................. 131/351
`Hajaligol et al. ....................... 131/359
`Deevi et al ............................. 131/194
`Blackburn ............................... 219/268
`Morgan et al. ......................... 131/194
`Counts et al.
`... ....... ... ... ...... .... 131/194
`Blackburn ............................... 219/268
`Blackburn ............................... 219/268
`Counts et al..
`..................... 131/194 X
`Counts et al.
`.......................... 131/194
`
`Ex. 2018-0002
`
`

`

`U.S. Patent
`US. Patent
`
`Feb. 2, 1999
`Feb. 2, 1999
`
`Sheet 1 0f 12
`Sheet 1 of 12
`
`5,865,185
`5,865,185
`
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`Ex. 2018-0003
`
`Ex. 2018-0003
`
`

`

`U.S. Patent
`US. Patent
`
`Feb. 2, 1999
`Feb. 2, 1999
`
`Sheet 2 0f 12
`Sheet 2 of 12
`
`5,865,185
`5,865,185
`
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`
`Ex. 2018-0004
`
`Ex. 2018-0004
`
`

`

`U.S. Patent
`
`Feb.2, 1999
`
`Sheet 3 of 12
`
`5,865,185
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`Ex. 2018-0005
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`

`U.S. Patent
`
`Feb. 2, 1999
`
`Sheet 4 of 12
`
`5,865,185
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`U.S. Patent
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`Fch. 2, 1999
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`

`U.S. Patent
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`Feb. 2, 1999
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`Sheet 6 of 12
`
`5,865,185
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`Ex. 2018-0008
`
`

`

`U.S. Patent
`US. Patent
`
`Feb. 2, 1999
`Feb. 2, 1999
`
`Sheet 7 0f 12
`Sheet 7 of 12
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`5,865,185
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`Ex. 2018-0009
`
`

`

`U.S. Patent
`US. Patent
`
`Feb. 2
`Feb. 2, 1999
`, 1999
`
`Sheet 8 0f 12
`Sheet 8 of 12
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`Ex. 2018-0010
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`

`U.S. Patent
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`Feb. 2, 1999
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`Sheet 9 of 12
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`5,865,185
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`

`

`U.S. Patent
`US. Patent
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`Feb.2, 1999
`Feb. 2, 1999
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`Ex. 2018-0013
`
`

`

`U.S. Patent
`
`Feb. 2, 1999
`
`Sheet 12 of 12
`
`5,865,185
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`Ex. 2018-0014
`
`

`

`5,865,185
`
`1
`FLAVOR GENERATING ARTICLE
`
`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.
`
`BACKGROUND OF THE INVENTION
`
`5
`
`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
`10 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
`15 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(cid:173)
`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(cid:173)
`facturing processes for such an article that can be imple(cid:173)
`mented using conventional high-volume assembly machin-
`ery.
`
`This invention relates to smoking articles in which
`tobacco flavor media are heated to release tobacco flavors.
`More particularly, this invention relates to electrically 20
`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 25
`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 30
`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 35
`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 40
`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 55
`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(cid:173)
`ing in variations in power consumption which, in turn, can 60
`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. 65
`Pat. No. 5,060,671 are addressed by above-incorporated
`copending, commonly-assigned U.S. patent application Ser.
`
`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(cid:173)
`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(cid:173)
`facturing processes for such an article that can be imple(cid:173)
`mented using conventional high-volume assembly machin(cid:173)
`ery.
`In accordance with this invention, there is provided a
`removable tobacco flavor unit for use in a smoking article
`45 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,
`50 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
`
`Ex. 2018-0015
`
`

`

`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 5
`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, 10
`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 15
`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.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`30
`
`The above and other objects and advantages of the present
`invention will be apparent upon consideration of the fol(cid:173)
`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 35
`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 45
`article of FIGS. 1-4, taken from line 5-5 of FIG. 2;
`FIG. 6 is a preferred embodiment of apparatus for manu(cid:173)
`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 50
`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 60
`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;
`
`5,865,185
`
`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. llAis a radial cross-sectional view of the permanent
`heaterunit ofFIG.10, taken from line llA-llAof FIG.10;
`FIG. llB is a radial cross-sectional view of the permanent
`heaterunit ofFIG.10, taken from line llB-llB 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-
`20 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(cid:173)
`densate. The disposable tobacco flavor unit can also include,
`25 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(cid:173)
`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(cid:173)
`assigned U.S. Pat. No. 5,060,671, which is hereby incorpo-
`40 rated by reference.
`The reusable or permanent portion includes a permanent
`cavity at the mouth end thereof for insertion of the dispos(cid:173)
`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,
`55 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
`65 provided, as in the present invention.
`The permanent heaters of the present invention are iso(cid:173)
`lated from the tobacco flavor air passageway and aerosol
`
`Ex. 2018-0016
`
`

`

`5,865,185
`
`5
`cavity. This isolation mm1mizes 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(cid:173)
`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 15
`configuration, as discussed below, should preferably be
`thermally stable so as to be able to withstand the tempera(cid:173)
`tures produced by the permanent heaters, and should pref(cid:173)
`erably also be thermally transmissive to allow the heat
`generated by the permanent heaters to be efficiently trans(cid:173)
`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(cid:173)
`closed in copending, commonly-assigned U.S. patent appli(cid:173)
`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 30
`g/m2 to about 12 g/m2 with fiber diameters between about 7
`µm and about 30 µm). 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., 35
`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 40
`sheets, foams, gels, dried slurries, or dried spray-deposited
`slurries, which may or may not contain tobacco or tobacco(cid:173)
`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- 50
`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, 55
`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 60
`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(cid:173)
`termined portion of the non-uniform tobacco flavor material. 65
`Additionally, flavor delivery can also be selectively varied
`in accordance with present invention by providing a con-
`
`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
`5 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
`10 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(cid:173)
`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
`20 second. Therefore, the first unit will generate more aerosol
`or flavorants per puff than the second, assuming the tem(cid:173)
`perature is not high enough to cause undesirable burning of
`the tobacco flavor material. In this manner the generation of
`aerosol or flavor ants can be selectively controlled by varying
`25 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 inser