`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 1 of 34 Page|D# 16970
`
`
`
`
`
`
`EXHIBIT 4
`
`EXHIBIT 4
`
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 2 of 34 PageID# 16971
`US006040560A
`United States Patent [i9j
`[ii] Patent Number:
`[45] Date of Patent:
`Fleischhauer et al.
`
`6,040,560
`Mar. 21,2000
`
`[54] POWER CONTROLLER AND METHOD OF
`OPERATING AN ELECTRICAL SMOKING
`SYSTEM
`
`[75] Inventors: Grier S. Fleischhauer, Midlothian;
`Charles T. Higgins; D. Bruce Losee,
`both of Richmond, all of Va.; J. Robert
`Nelson, Jr., Easton, Conn.; Robert L.
`Ripley, Midlothian, Va.; Masato Sano,
`Sumoto, Japan; David E. Sharpe,
`Chesterfield; Michael L. Watkins,
`Chester, both of Va.
`
`[73] Assignee: Philip Morris Incorporated, New
`York, N.Y.
`
`[21] Appl. No.: 08/951,255
`Oct. 16, 1997
`[22] Filed:
`
`Related U.S. Application Data
`
`[63] Continuation-in-part of application No. 08/755,044, Oct. 22,
`1996, abandoned.
`[51] Int. Cl.7 ................................................... H05B 1/02
`[52] U.S. Cl........................... 219/494; 219/483; 219/501;
`219/497; 219/492; 128/202.21; 131/329
`[58] Field of Search .................................. 219/494, 497,
`219/499, 501, 505, 483, 485, 486, 492;
`131/194, 270, 271, 329, 273; 128/202.21,
`202.27
`
`[56]
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`6/1987 Reinold et al.............................. 219/509
`4/1991 Lee ............................................ 219/492
`7/1991 Fishman ................................... 219/497
`11/1993 Todd et al.................................. 219/483
`12/1994 McCafferty et al....................... 131/194
`
`4,669,430
`5,004,881
`5,036,181
`5,260,548
`5,372,148
`
`Primary Examiner—Mark Paschall
`Attorney, Agent, or Firm—Charles E. B. Glenn; Kevin B.
`Osborne; Clinton H. Hallman, Jr.
`ABSTRACT
`[57]
`A novel controller in an electrical smoking system and
`method, wherein the method includes the steps of: estab
`lishing a preferred thermal pathway to be executed with each
`heater activation responsively to a puff on an electrically
`heated cigarette; configuring a power cycle in accordance
`with the desired thermal pathway; dividing the power cycle
`into at least first and second phases each having a respective,
`predetermined time period and total energy input for each
`phase; and adjusting a respective duty cycle (or other
`power-adjusting factor) in each phase of the power cycle
`responsively to a voltage reading of the power source such
`that the established, respective total energy input of each
`phase is achieved during the time period of each power
`cycle.
`
`82 Claims, 17 Drawing Sheets
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 3 of 34 PageID# 16972
`U.S. Patent
`6,040,560
`
`Mar. 21,2000
`
`Sheet 1 of 17
`
`FIG.
`
`cr>
`OJ
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 4 of 34 PageID# 16973
`U.S. Patent
`6,040,560
`
`Mar. 21,2000
`
`Sheet 2 of 17
`
`FIG.
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 5 of 34 PageID# 16974
`U.S. Patent
`6,040,560
`
`Mar. 21,2000
`
`Sheet 3 of 17
`
`FIG.
`
`186
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 6 of 34 PageID# 16975
`U.S. Patent
`6,040,560
`
`Mar. 21,2000
`
`Sheet 4 of 17
`
`FIG.
`
`50α'
`
`122
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 7 of 34 PageID# 16976
`U.S. Patent
`6,040,560
`
`Mar. 21,2000
`
`Sheet 5 of 17
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 8 of 34 PageID# 16977
`U.S. Patent
`6,040,560
`
`Mar. 21,2000
`
`Sheet 6 of 17
`
`FIG.
`
`o
`00
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 9 of 34 PageID# 16978
`U.S. Patent
`6,040,560
`
`Mar. 21,2000
`
`Sheet 7 of 17
`
`308
`
`309
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 10 of 34 PageID# 16979
`U.S. Patent
`6,040,560
`
`Mar. 21,2000
`
`Sheet 8 of 17
`
`USE τ
`
`Fig- 8
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 11 of 34 PageID# 16980
`U.S. Patent
`6,040,560
`
`Mar. 21,2000
`
`Sheet 9 of 17
`
`Heater Temperature Target
`
`(3) aunq.Ouadua_[ ^naj
`
`Qsn -
`
`900 η
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 12 of 34 PageID# 16981
`U.S. Patent Mar. 21,2000 Sheet 10 of 17
`6,040,560
`
`(6|3/6uj)
`hldl
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 13 of 34 PageID# 16982
`U.S. Patent
`6,040,560
`
`Sheet 11 of 17
`
`Mar. 21, 2000
`
`<T
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 14 of 34 PageID# 16983
`U.S. Patent
`6,040,560
`
`Sheet 12 of 17
`
`Mar. 21, 2000
`
`ω
`
`(3) a
`
`006
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 15 of 34 PageID# 16984
`U.S. Patent
`6,040,560
`
`Sheet 13 of 17
`
`Mar. 21, 2000
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 16 of 34 PageID# 16985
`U.S. Patent
`6,040,560
`
`Sheet 14 of 17
`
`Mar. 21, 2000
`
`TIME <sec)
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 17 of 34 PageID# 16986
`U.S. Patent
`6,040,560
`
`Sheet 15 of 17
`
`Mar. 21, 2000
`
`Vin - VDC
`
`ΟΟΌΟΙ
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 18 of 34 PageID# 16987
`U.S. Patent
`6,040,560
`
`Sheet 16 of 17
`
`Mar. 21, 2000
`
`Vin - VDC
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 19 of 34 PageID# 16988
`U.S. Patent
`6,040,560
`
`Sheet 17 of 17
`
`Mar. 21, 2000
`
`41 '
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 20 of 34 PageID# 16989
`
`1
`POWER CONTROLLER AND METHOD OF
`OPERATING AN ELECTRICAL SMOKING
`SYSTEM
`
`This is a continuation-in-part of U.S. patent application
`Ser. No. 08/755,044 filed Oct. 22, 1996, now abandoned.
`FIELD OF INVENTION
`This invention relates to electrically powered smoking
`articles, and particularly to methods and apparatus for con
`trolling the supply of energy to electrically powered smok
`ing articles.
`BACKGROUND OF THE INVENTION
`Commonly assigned, U.S. Pat. Nos. 5,388,594, 5,505,
`214, and 5,591,368 disclose various electrically operated
`lighters and cigarettes which cooperate to significantly
`reduce sidestream smoke while permitting the smoker to
`selectively suspend and reinitiate smoking. U.S. Ser. No.
`08/380,718 was preceded by a commonly assigned patent
`application which issued as U.S. Pat. No. 5,388,594 (PM
`1697).
`The preferred embodiment of the lighter in U.S. Pat. No.
`5,388,594 includes a plurality of metallic serpentine heaters
`disposed in a configuration that slidingly receives a tobacco
`rod portion of the system’s 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 puff, localized charring occurs at spots about the
`cigarette in the locality where each heater bears against the
`cigarette (hereinafter referred to as a “heater footprint”).
`In U.S. Pat. No. 5,388,594, the sequence and the amount
`of energy applied to each heater element during a puff cycle
`is regulated by a logic circuit of a controller which executes
`a power subroutine upon its receiving a signal from a puff
`sensor that a puff has been initiated. The power subroutine
`includes the steps of reading the voltage of the power source
`(batteries) at the initiation of the puff and resolving a shut-off
`signal to a constant Joules energy timer such that the
`duration of the pulse (its cycle-period) is adjusted relative to
`the voltage of the power source to provide the same total
`amount of energy (Joules) throughout the range of voltages
`of the battery discharge cycle. It has been discovered that
`this sort of power subroutine may provide the smoker a
`different tasting smoking experience at the extremes of the
`battery discharge cycle. At full battery voltage, this type of
`control circuit would heat a cigarette more intensively for a
`shorter pulse duration than a cigarette smoked near or at the
`conclusion of the battery discharge cycle, where the ciga
`rette would be heated at lower power for a longer period of
`time (pulse cycle).
`Accordingly, a need has been perceived for a controller in
`an electrically operated cigarette lighter which duplicates the
`thermal treatment of a cigarette throughout the discharge
`cycle of its batteries/power source.
`In commonly assigned U.S. Pat. No. 5,372,148 to McCaf
`ferty et al, a controller for an electrical smoking system is
`disclosed having a power subroutine that includes the steps
`of reading battery voltage and setting an estimated pulse
`duration length (e.g. 1 second) and dividing the cycle into a
`number of intervals (e.g. 10 intervals, each 100 milli
`seconds), wherein the amount of energy required to generate
`aerosol is proportioned among the intervals in substantially
`equal factional amounts. During execution of the cycle, the
`controller monitors the amount of energy supplied to the
`selected heater element during each power interval and
`
`5
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`6,040,560
`
`2
`continues application of power until the correct proportional
`amount of energy has been delivered during the interval.
`Because the power scheme of U.S. Pat. No. 5,372,148
`changes cycle duration responsively to battery voltage, the
`power subroutine will change the thermal treatment of the
`cigarette as the batteries proceed through their discharge
`voltage cycles.
`In U.S. Pat. No. 4,947,874 to Brooks et al, a smoking
`article includes a singular electrical resistance heating ele
`ment that is impregnated with aerosol forming material and
`which is heated in a succession of power cycles. The article
`includes a current regulating circuit which provides an
`uninterrupted current flow immediately upon draw for about
`1.5 to about 2 seconds followed by an “off” period of about
`0.5 to about 1 second. The patent also proposes an alterna
`tive to an on-off time-based circuit, which alterative would
`include on-off and current modulating means connected to
`temperature sensors or other sensors that would sense either
`the temperature of the heating element directly or the
`temperature of air passing the heating element or the tem
`perature of a second resistor having a character related to
`that of the aerosol carrying heating element.
`The article disclosed in U.S. Pat. No. 4,947,874 is disad
`vantaged by its repetitively heating a singular heater and the
`material impregnated thereon, which creates a situation of
`already depleted tobacco material being heated again and
`again. Additionally, targeting temperature at different battery
`voltages may affect the rate at which energy is supplied to
`the heater, which in turn could affect how the article ther
`mally treats the aerosol forming material.
`OBJECTS AND SUMMARY OF INVENTION
`A central object of the present invention is to provide a
`controller and method of applying power within an electrical
`cigarette system wherein the thermal pathway for enhancing
`smoke delivery can be established and then repeated pre
`cisely throughout the battery discharge cycle of the electrical
`lighter.
`Another object of the present invention is to provide an
`electrical cigarette lighter which delivers consistent smoke
`throughout the discharge cycle of its batteries.
`Yet another object of the present invention is to provide,
`in connection with the design of a lighter of an electrical
`smoking system, a methodology for determining a thermo
`histogram that enhances smoke delivery without imposing
`excessive temperatures in the heater elements, together with
`a methodology for configuring the controller of the lighter
`for precise execution of the predetermined thermo
`histogram so that thermal treatment of each cigarette by the
`lighter is precisely repeated puff after puff and cigarette after
`cigarette and so that the useful life of the heater elements is
`prolonged.
`Another object of the present invention is to provide a
`segmented power application cycle in the lighter of an
`electrical smoking system, whose cycle parameters may be
`manipulated and matched with heater geometries so as to
`achieve desired subjective results in taste, impact and aroma
`of the smoke produced by the electrical cigarette system, so
`that consumer preferences may be met.
`These and other objects are achieved in the present
`invention which provides an apparatus and method of con
`trolling the application of power cycles in an electrical
`smoking system so that the smoking system provides con
`sistent delivery from puff to puff and throughout a discharge
`cycle of its batteries (or other power source). Preferably, the
`electrical smoking system includes a lighter which com-
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 21 of 34 PageID# 16990
`
`6,040,560
`
`4
`FIG. 9 is a graphical representation of the relationship
`between peak temperature (°C.) relative to energy input
`(Joules) in the heater element of the type shown in FIG. 5;
`FIG. 10 is a graphical representation of the relationship
`between total particulate matter (IBM) in milligrams per
`cigarette versus the total energy input (Joules) for power
`cycles executed with a constant power profile and a one-
`second pulse, using a 10x12 millimeter straight hairpin
`heater element (of the type shown in FIG. 5) and an 8x16
`millimeter wavey hairpin heater element (of the type shown
`in FIG. 4);
`FIG. 11 is a graphical representation of a preferred
`two-phase thermal-histogram;
`FIG. 12 is an illustration of heater temperature versus time
`during a first high power phase followed by a second low
`power phase of power modulation throughout a phased
`power cycle;
`FIG. 13 is a diagram illustrating the various characteris
`tics of a pulsed wave form produced by the logic circuit of
`the preferred embodiment;
`FIG. 14 is another preferred histogram for a power cycle
`as established following methodology encompassed by a
`preferred embodiment of the present invention;
`FIG. 15 is a graphical representation of peak wattage
`verses time as detected by a digital analyzer of the power
`cycle produced by the control circuit of the preferred
`embodiment when the battery voltage is at a fully charged
`state of 5.2 volts;
`FIG. 16 is a graphical representation of peak wattage
`versus time as detected by a digital analyzer of the power
`cycle produced by the control circuit of the preferred
`embodiment when the battery voltage is at a nearly depleted
`state of 3.8 volts;
`FIG. 17 is a graphical representation of duty cycles in the
`first and second phases of a preferred power cycle versus the
`battery voltage v/n;
`FIG. 18 is a graphical representation of energy (the total
`Joules and the Joules of phases 1 and 2) verses v,-„; and
`FIG. 19 is a schematic, block-diagram of a control circuit
`for the lighter shown in FIGS. 1 and 2, with the control
`circuit arranged in accordance with another preferred
`embodiment of the present invention.
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENTS
`Referring to FIGS. 1 and 2, a preferred embodiment of the
`present invention provides a smoking system 21 which
`preferably includes a partially-filled, filler cigarette 23 and a
`reusable lighter 25. The cigarette 23 is adapted to be inserted
`into and removed from a receptacle 27 at a front end portion
`29 of the lighter 25. Once the cigarette 23 is inserted, the
`smoking system 21 is used in much the same fashion as a
`more traditional cigarette, but without lighting or smolder
`ing of the cigarette 23. The cigarette 23 is discarded after one
`or more puff cycles. Preferably, each cigarette 23 provides a
`total of eight puffs (puff cycles) or more per smoke; however
`it is a matter of design expedient to adjust to a lesser or
`greater total number of available puffs.
`The smoking system is described in greater detail in the
`commonly assigned U.S. Pat. No. 5,388,594 and in com
`monly assigned U.S. Pat. No. 5,388,594, which are hereby
`incorporated by reference in their entireties. Hie partially-
`filled, filler cigarette 23 is further described in the commonly
`assigned, U.S. Pat. No. 5,499,636, which is hereby incor
`porated by reference in its entirety.
`
`3
`prises a source of electrical power, a plurality of heater
`elements and a controller for controllably communicating at
`least one of said heater elements with the electrical power
`source during a power cycle.
`The novel method includes the steps of: establishing a
`preferred thermal pathway (or “thermo-histogram”) to be
`executed with each heater activation responsively to a puff;
`and configuring the power cycle in accordance with the
`desired thermo-histogram. The latter step includes dividing
`the power cycle into at least first and second phases each
`having a respective, predetermined time period and total
`energy input for each phase. The method further comprises
`the steps of predetermining a discharge cycle of the power
`source (its upper and lower limits of operational voltage
`variation) and repetitively executing the configured power
`cycle upon demand by determining the real time voltage of
`the power source and adjusting a respective duty cycle (or
`other power-adjusting factor) in each phase of the power
`cycle responsively to the voltage reading such that the
`established, respective total energy input of each phase is
`achieved during the execution of each power cycle.
`Accordingly, the controller renders precise repetition of the
`desired thermo-histogram throughout the discharge cycle of
`the power source.
`Another aspect of the present invention is an alternate
`method of executing a power cycle in accordance with a
`prescribed thermo-histogram by reading the real time loaded
`voltage of the power source and the real time current through
`the heater element and adjusting a respective duty cycle
`(preferably, by adjusting pulse density) in each phase of the
`power cycle responsively to the voltage and current readings
`such that the established, respective average power of each
`phase is achieved during the execution of each power cycle.
`Yet another aspect of the present invention is the step of
`configuring the first and second (or more) phases of the
`power cycle so as to avoid excessive temperature peaks in
`the heater element and extend their serviceable life
`expectancies.
`BRIEF DESCRIPTION OF THE DRAWING
`Other objects, advantages and novel features of the
`present invention will become apparent from the following
`detailed description of the preferred embodiments of the
`present invention when considered in conjunction with the
`accompanying drawing, in which:
`FIG. 1 is a perspective view of a smoking system in
`accordance with a preferred embodiment of the present
`invention with a cigarette thereof inserted into the electri
`cally operated lighter;
`FIG. 2 is a perspective view of the smoking system of
`FIG. 1, but with the cigarette withdrawn from the lighter
`upon conclusion of a smoking;
`FIG. 3 is a partially broken, perspective detail of a
`preferred heater fixture of the lighter shown in FIG. 1 and
`including serpentine heater elements;
`FIG. 4 is a sectional side view of an alternate, preferred
`heater fixture which includes wavy hairpin heater elements;
`FIG. 5 is a sectional side-view of another preferred heater
`fixture which includes straight hairpin heater elements;
`FIG. 6 is a detailed perspective view of the cigarette
`shown in FIGS. 1 and 2, with certain components of the
`cigarette being partially unraveled;
`FIG. 7 is a schematic, block-diagram of a control circuit
`for the lighter shown in FIGS. 1 and 2;
`FIG. 8 is a graphical representation of a typical battery
`discharge cycle associated with the power source of the
`lighter shown in FIGS. 1 and 2;
`
`5
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 22 of 34 PageID# 16991
`
`6,040,560
`
`5
`The lighter 25 includes a housing 31 having front and rear
`housing portions 33 and 35. One or more batteries 35α are
`removably located within the rear housing portion 35 and
`supply energy to a plurality of electrically resistive, heating
`elements 37 (shown in FIG. 2) which are arranged within the
`front housing portion 33 adjacent the receptacle 27. A
`control circuit 41 in the front housing portion 33 establishes
`electrical communication between the batteries 35α and the
`heater elements 37. The preferred embodiment of the present
`invention includes details concerning the control circuit 41,
`which are discussed in greater detail beginning with refer
`ence to FIG. 7.
`Still referring to FIGS. 1 and 2, preferably the rear portion
`35 of the lighter housing 31 is adapted to be readily opened
`and closed, such as with screws or snap-fit components, so
`as to facilitate replacement of the batteries. If desired, an
`electrical socket or contacts may be provided for recharging
`the batteries with house current or the like. Preferably, the
`front housing portion 33 is removably joined to the rear
`housing portion 35, such as with a dovetail joint or a socket
`fit.
`
`The batteries 35α are sized to provide sufficient power for
`the heaters 37 to function as intended and preferably com
`prise a replaceable and rechargeable type. Alternate sources
`of power are suitable, such as capacitors. In the preferred
`embodiment, the power source comprises four nickel
`cadmium battery cells connected in series with a total,
`non-loaded voltage in the range of approximately 4.8 to 5.6
`volts. The characteristics of the power source are, however,
`selected in view of the characteristics of other components
`in the smoking system 21, particularly the characteristics of
`the heating elements 37. Commonly assigned, U.S. Pat. No.
`5,144,962, hereby incorporated by reference, describes sev
`eral types of power sources useful in connection with the
`smoking system of the present invention, such as recharge
`able battery sources and power arrangements which com
`prise a battery and a capacitor which is recharged by the
`battery.
`Referring specifically to FIG. 2, preferably, the circuitry
`41 is activated by a puff-actuated sensor 45 that is sensitive
`to either changes in pressure or changes in rate of air flow
`that occur upon initiation of a draw on the cigarette 23 by a
`smoker. The puff-actuated sensor 45 is preferably located
`within the front housing portion 33 of the lighter 25 and is
`communicated with a space inside the heater fixture 39
`adjacent the cigarette 23 through a passageway extending
`through a stop 182 located at the base of the heater fixture
`39. A puff-actuated sensor 45 suitable for use in the smoking
`system 21 is described in commonly assigned, U.S. Pat. No.
`5,060,671 and commonly assigned U.S. Pat. No. 5,388,594,
`the disclosures of which are incorporated herein by refer
`ence. The puff sensor 45 preferably comprises a Model
`163PCO1D35 silicon sensor, manufactured by the
`MicroSwitch division of Honeywell, Inc., Freeport, Ill. Flow
`sensing devices, such as those using hot-wire anemometry
`principles, have also been successfully demonstrated to be
`useful for activating an appropriate one of the heater ele
`ments 37 upon detection of a change in air flow. Once
`activated by the sensor 45, the control circuitry 41 directs
`electric current to an appropriate one of the heater elements
`37.
`An indicator 51 is provided at a location along the exterior
`of the lighter 25, preferably on the front housing portion 33,
`to indicate the number of puffs remaining in a smoke of a
`cigarette 23. The indicator 51 preferably includes a seven
`segment liquid crystal display. In the preferred embodiment,
`the indicator 51 displays the digit “8” when a cigarette
`
`6
`detector 53 detects the presence of a cigarette in the heater
`fixture 39. The detector 53 preferably comprises a light
`sensor adjacent the open end of the cigarette receptacle 27
`that detects when a beam of light is reflected off (or
`alternatively, transmitted through) an inserted cigarette 23.
`Thereupon, the cigarette detector 53 provides a signal to the
`circuitry 41 which, in turn, responsively provides a signal to
`the indicator 51. The display of the digit “8” on the indicator
`51 reflects that the eight puffs provided on each cigarette 23
`are available, i.e., none of the heater elements 37 have been
`activated to heat the cigarette 23. After the cigarette 23 is
`fully smoked, the indicator displays the digit “0”. When the
`cigarette 23 is removed from the lighter 25, the cigarette
`detector 53 no longer detects a presence of a cigarette 23 and
`the indicator 51 is turned off. The cigarette detector 53 is
`modulated so that it does not constantly emit a beam of light,
`which would otherwise create an unnecessary drain on the
`power source 35α. A preferred cigarette detector 53 suitable
`for use with the smoking system 21 is a Type OPR5005
`Light Sensor, manufactured by OPTEX Technology, Inc.,
`1215 West Crosby Road, Carrollton, Tex. 75006. In the
`alternative, the detector 53 may comprise a source of infra
`red light and a sensor opposite thereof which senses changes
`in infrared transmissivity across the receptacle 27.
`In the alternative to displaying the remainder of the puff
`count, the detector display may instead be arranged to
`indicate whether the system is active or inactive (“on” or
`“off”).
`As one of several possible alternatives to using the
`above-noted cigarette detector 53, a mechanical switch (not
`shown) may be provided to detect the presence or absence
`of a cigarette 23 and a reset button (not shown) may be
`provided for resetting the circuitry 41 when a new cigarette
`is inserted into the lighter 25, e.g., to cause the indicator 51
`to display the digit “8”, etc. Power sources, circuitry, puff-
`actuated sensors, and indicators useful with the smoking
`system 21 of the present invention are described in com
`monly assigned, U.S. Pat. No. 5,060,671 (PM 1337), U.S.
`Pat. No. 5,388,594 and the commonly assigned, U.S. Pat.
`5,505,214, all which are incorporated by reference.
`Referring now also to FIG. 8, the preferred four cells of
`nickel cadmium batteries 35α typically have a voltage
`discharge cycle such as the one which is generally desig
`nated 40 in FIG. 8. The discharge cycle is representative of
`the change in output voltage (νΛ·„) of the batteries 35α
`throughout their use from a fully charged state vin.max
`(preferably at or about 5.1 volts in the preferred
`embodiment) to a preselected minimum voltage Nin.min,
`preferably at or about 4.1 volts in the preferred embodiment.
`Preferably, the lower “cut-off” voltage is established
`slightly above a “basement” voltage vin.min, which is known
`to be too low for consistent operation of the lighter 25.
`Referring now to FIG. 3, the front housing portion 33 of
`the lighter 25 supports a substantially cylindrical heater
`fixture 39 which slidingly receives the cigarette 23. The
`heater fixture 39 houses the heater elements 37 and is
`adapted to support an inserted cigarette 23 in a fixed relation
`to the heater elements 37 such that the heater elements 37 are
`positioned alongside the cigarette 23 at approximately the
`same location along each cigarette. The locations where
`each heater element 37 bears against (or is in thermal contact
`with) a fully inserted cigarette 23 is referred to herein as the
`heater footprint.
`To assure consistent placement of the heating elements 37
`relative to each cigarette 23 from cigarette to cigarette, the
`heater fixture 39 is provided with a stop 182 against which
`
`5
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`
`
`Case 1:20-cv-00393-LO-TCB Document 696-4 Filed 06/02/21 Page 23 of 34 PageID# 16992
`
`6,040,560
`
`7
`the cigarette is urged during its insertion into the lighter 25.
`Other expedients for registering the cigarette 23 relative to
`the lighter 25 could be used instead.
`The front housing portion 33 of the lighter 25 also
`includes an electrical control circuitry 41 which delivers a
`predetermined amount of energy from the power source 35α
`to the heating elements 37. In the preferred embodiment, the
`heater fixture 39 includes eight circumferentially spaced
`apart heating elements 37 which are concentrically aligned
`with the receptacle 27 so as to slidingly receive a cigarette
`23. They preferably include a serpentine form. Details of the
`construction and establishment of electrical connections in
`the heater fixture 39 are illustrated and described in com
`monly assigned U.S. Pat. Nos. 5,388,594; 5,505,214; and
`5,591,368, all which documents are incorporated herein by
`reference in their entireties.
`Referring now to FIG. 4, most preferably the heater
`elements 37 are of a design referred to herein as a wavey
`hairpin 37', wherein each heater element 37' includes at least
`first and second serpentine, elongate members 50α and 50b
`which are adjoined at an end portion 118. An electrical
`pathway through each heater fixture 37' is established,
`respectively, through a pin 104, a connection 122 between
`the pin 104 and one of the serpentine members 50α, through
`at least a portion of the end portion 118 to the other
`serpentine member 50b and back to a base portion 110 of the
`heater element 37'. The base portion 110 provides a common
`connection of all serpentine members 50b with a second pin
`105 through a connection 123 between the base portion 110
`and the pin 105. Further details of this heater fixture 39' are
`set forth in the commonly-assigned U.S. Pat. No. 5,591,368,
`hereby incorporated by reference in its entirety.
`Referring now to FIG. 5, another preferred design
`includes heater elements in the form of a straight hairpin 37"
`which is connected and structured similarly to the wavey
`hairpin element 37' of FIG. 4, except that the elongate
`members 50α" and 50b" are generally straight instead of
`serpentine. The elongate members of both types of hairpin
`heaters are preferably biased inwardly to more positively
`engage a cigarette 23. Details of this heater fixture 39" are
`set forth in the same U.S. Pat. No. 5,591,368.
`Referring now to FIG. 3, yet another preferred heater
`fixture 39 includes “singular serpentine” elements 37, each
`which is electrically connected at its opposite ends to a
`control circuit through leads 186 and 187. Details concern
`ing this heater fixture 37 are set forth in commonly assigned
`U.S. Pat. No. 5,388,594 (PM 1697), incorporated by refer
`ence in its entirety.
`Additional heater fixtures 37 that are operable as part of
`the lighter 25 include those disclosed in commonly assigned
`U.S. Pat. No. 5,665,262 and 5,498,855, which are incorpo
`rated herein by reference in their entireties.
`Preferably, the heaters 37 are individually energized by
`the power source 35α under the control of the circuitry 41 to
`heat the cigarette 23 preferably eight times at spaced loca
`tions about the periphery of the cigarette 23. The heating
`renders eight puffs from the cigarette 23, as is commonly
`achieved with the smoking of a more traditional cigarette. It
`may be preferred to activate more than one heater simulta
`neously for one or more or all of the puffs.
`Referring now to FIG. 6, the cigarette 23 is preferably
`constructed in accordance with the preferred embodiment
`set forth in commonly assigned, U.S. Pat. No. 5,499,636,
`herein incorporated by reference in its entirety.
`The cigarette 23 comprises a tobacco rod 60 and a filter
`tipping 62, which are joined together with tipping paper 64.
`
`5
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`8
`The tobacco rod 60 of the cigarette 23 preferably includes
`a tobacco web 66 which has been folded into a tubular
`(cylindrical) form about a free-flow filter 74 at one of its
`ends and a tobacco plug 80 at the other.
`An overwrap 71 is intimately wrapped about the tobacco
`web 66 and is held together along a longitudinal seam as is
`common in construction of more traditional cigarettes. The
`overwrap 71 retains the tobacco web 66 in a wrapped
`condition about a free-flow filter 74 and a tobacco plug 80.
`The tobacco web 66 itself preferably comprises a base
`web 68 and a layer of tobacco flavor material 70 located
`along the inside surface of the base web 68. At the tipped end
`72 of the tobacco rod 60, the tobacco web 66 together with
`the overwrap 71 are wrapped about the tubular free-flow
`filter plug 74. Preferably, the tobacco plug 80 is constructed
`separately from the tobacco web 66 and comprises a rela
`tively short column of cut filler tobacco that has been
`wrapped within and retained by a plug wrap 84.
`As a general matter, the length of the tobacco plug 80 is
`preferably set relative to the total length of the tobacco rod
`60 such that a void 90 is established along the tobacco rod
`60 b