AEROSOL DELIVERY DEVICE WITH ALTERNATIVE CONSUMABLE LOADING AND EJECTION CONFIGURATIONS

Abstract

Disclosed is an aerosol delivery device for use with removable and replaceable cartridges that may be loaded into and ejected from the devices in different orientations and via different access points. The device includes a holder defining a proximal end and a distal end and a receiving chamber configured to receive the removable cartridge. The holder defines a first aerosol passageway extending therethrough. The device may include a mouthpiece coupled to the holder and defining a second aerosol passageway extending therethrough. The device may further include an access point (e.g., a door) movably coupled to the holder. In an open configuration, the access point provides access to the receiving chamber for loading the removable cartridge therein and, in a closed configuration, fluidly couples the receiving chamber with the first aerosol passageway.

Description

FIELD OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices and systems, such as smoking articles; and more particularly, to aerosol delivery devices and systems that utilize heat sources, such as combustible carbon-based ignition sources, for the production of an aerosol (e.g., smoking articles for purposes of yielding components of tobacco, tobacco extracts, nicotine, synthetic nicotine, non-nicotine flavoring, and other materials in an inhalable form, commonly referred to as heat-not-burn systems or electronic cigarettes). Components of such articles may be made or derived from tobacco, or those articles may be characterized as otherwise incorporating tobacco for human consumption, and which may be capable of vaporizing components of tobacco and/or other tobacco related materials to form an inhalable aerosol for human consumption.

BACKGROUND

Many smoking articles have been proposed through the years as improvements upon, or alternatives to, smoking products based upon combusting tobacco. Example alternatives have included devices wherein a solid or liquid fuel is combusted to transfer heat to tobacco or wherein a chemical reaction is used to provide such heat source. Examples include the smoking articles described in U.S. Pat. No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

The point of the improvements or alternatives to smoking articles typically has been to provide the sensations associated with cigarette, cigar, or pipe smoking, without delivering considerable quantities of incomplete combustion and pyrolysis products. To this end, there have been proposed numerous smoking products, flavor generators, and medicinal inhalers which utilize electrical energy to vaporize or heat a volatile material, or attempt to provide the sensations of cigarette, cigar, or pipe smoking without burning tobacco to a significant degree. See, for example, the various alternative smoking articles, aerosol delivery devices and heat generating sources set forth in the background art described in U.S. Pat. No. 7,726,320 to Robinson et al.; and U.S. Pat. App. Pub. Nos. 2013/0255702 to Griffith, Jr. et al.; and 2014/0096781 to Sears et al., which are incorporated herein by reference. See also, for example, the various types of smoking articles, aerosol delivery devices and electrically powered heat generating sources referenced by brand name and commercial source in U.S. Pat. App. Pub. No. 2015/0220232 to Bless et al., which is incorporated herein by reference. Additional types of smoking articles, aerosol delivery devices and electrically powered heat generating sources referenced by brand name and commercial source are listed in U.S. Pat. App. Pub. No. 2015/0245659 to DePiano et al., which is also incorporated herein by reference in its entirety. Other representative cigarettes or smoking articles that have been described and, in some instances, been made commercially available include those described in U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al.; U.S. Pat. No. 5,060,671 to Counts et al.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,388,594 to Counts et al.; U.S. Pat. No. 5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No. 7,832,476 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S. Pat. No. 7,726,320 to Robinson et al.; U.S. Pat. No. 7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan; U.S. Pat. App. Pub. No. 2009/0095311 to Hon; U.S. Pat. App. Pub. Nos. 2006/0196518, 2009/0126745, and 2009/0188490 to Hon; U.S. Pat. App. Pub. No. 2009/0272379 to Thorens et al.; U.S. Pat. App. Pub. Nos. 2009/0260641 and 2009/0260642 to Monsees et al.; U.S. Pat. App. Pub. Nos. 2008/0149118 and 2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub. No. 2010/0307518 to Wang; and WO 2010/091593 to Hon, which are incorporated herein by reference.

Various manners and methods for assembling smoking articles that possess a plurality of sequentially arranged segmented components have been proposed. See, for example, the various types of assembly techniques and methodologies set forth in U.S. Pat. No. 5,469,871 to Barnes et al. and U.S. Pat. No. 7,647,932 to Crooks et al.; and U.S. Pat. App. Pub. Nos. 2010/0186757 to Crooks et al.; 2012/0042885 to Stone et al., and 2012/00673620 to Conner et al.; each of which is incorporated by reference herein in its entirety.

Certain types of cigarettes that employ carbonaceous fuel elements have been commercially marketed under the brand names “Premier,” “Eclipse” and “Revo” by R. J. Reynolds Tobacco Company. See, for example, those types of cigarettes described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988) and Inhalation Toxicology, 12:5, p. 1-58 (2000). Additionally, a similar type of cigarette has been marketed in Japan by Japan Tobacco Inc. under the brand name “Steam Hot One.”

In some instances, some smoking articles, particularly those that employ a traditional paper wrapping material, are also prone to scorching of the paper wrapping material overlying an ignitable fuel source, due to the high temperature attained by the fuel source in proximity to the paper wrapping material. This can reduce enjoyment of the smoking experience for some consumers and can mask or undesirably alter the flavors delivered to the consumer by the aerosol delivery components of the smoking articles. In further instances, traditional types of smoking articles can produce relatively significant levels of gasses, such as carbon monoxide and/or carbon dioxide, during use (e.g., as products of carbon combustion). In still further instances, traditional types of smoking articles may suffer from poor performance with respect to aerosolizing the aerosol forming component(s).

As such, it would be desirable to provide smoking articles that address one or more of the technical problems sometimes associated with traditional types of smoking articles. In particular, it would be desirable to provide a smoking article that is easy to use and that provides reusable and/or replaceable components.

BRIEF SUMMARY

In various implementations, the present disclosure relates to aerosol delivery devices for use with removable and replaceable cartridges that may be loaded into or ejected from the devices in various orientations, such as, for example, a reverse configuration with an ignitable heat source first loaded into the device. The present disclosure includes, without limitation, the following example implementations.

Embodiment 1: An aerosol delivery device comprising a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source therein and further defining a first aerosol passageway that extends through at least a portion of the main body; a mouthpiece including a first end and a longitudinally opposed second end with a second aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the holder; and an access door movably coupled to the distal end of the main body and defining a third aerosol passageway, where, in an open configuration, the access door provides access to the receiving chamber for loading the removable cartridge therein and, in a closed configuration, fluidly couples the receiving chamber with the first aerosol passageway via the third aerosol passageway.

Embodiment 2: An aerosol delivery device comprising a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source therein and further defining a first aerosol passageway that extends through at least a portion of the main body; a mouthpiece including a first end and a longitudinally opposed second end with a second aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the holder; an access door movably coupled to the distal end of the main body and configured to provide access to the receiving chamber for loading the removable cartridge therein; and an opening defined by the main body and in fluid communication with the receiving chamber and oriented so as substantially align with the ignitable heat source when the removable cartridge is loaded within the receiving chamber.

Embodiment 3: An aerosol delivery device comprising a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source therein and further defining a first aerosol passageway that extends through at least a portion of the main body; an access door movably coupled to the distal end of the main body and defining a second aerosol passageway, wherein, in an open configuration, the access door provides access to the receiving chamber for loading the removable cartridge therein and, in a closed configuration, fluidly couples the receiving chamber with the first aerosol passageway via the second aerosol passageway; and an actuator assembly coupled to the holder and configured to contact the removable cartridge when loaded within the receiving chamber and eject the cartridge out of the distal end of the holder.

Embodiment 4: The aerosol delivery device of any one of the preceding Embodiments 1 to 3, wherein a sidewall of the holder defines an opening therethrough, the opening in fluid communication with the receiving chamber and disposed proximate the ignitable heat source when the removable cartridge is loaded within the receiving chamber. The opening may provide for air intake therethrough and/or viewing of the ignitable heat source

Embodiment 5: The aerosol delivery device of any one of Embodiment 1 to 4, or any combination thereof, further comprising a power source disposed within the main body and a pair of ignitor contacts in electrical communication with the power supply and disposed proximate the opening and configured to engage the ignitable heat source when the removable cartridge is loaded within the receiving chamber.

Embodiment 6: The aerosol delivery device of any one of Embodiments 1 to 5, or any combination thereof, further comprising an ignition switch in electrical communication with the power source and the ignitor contacts and configured to provide power to the contacts when actuated.

Embodiment 7: The aerosol delivery device of any one of Embodiments 1 to 6, or any combination thereof, further comprising a printed circuit board disposed within the holder and in electrical communication with the power source and comprising a controller.

Embodiment 8: The aerosol delivery device of any one of Embodiments 1 to 7, or any combination thereof, wherein the printed circuit board further comprises a charging port and the printed circuit board is oriented within the holder so that the charging port is disposed at one end of the holder.

Embodiment 9: The aerosol delivery device of any one of Embodiments 1 to 8, or any combination thereof, further comprising a slide mechanism configured to transition the access door from the closed configuration to the open configuration upon actuation thereof. The slide mechanism comprises a sliding button assembly disposed proximate the distal end of the main body and configured to engage a lip of the access door to transition the door into the open configuration.

Embodiment 10: The aerosol delivery device of any one of Embodiments 1 to 9, or any combination thereof, wherein the access door is coupled to the main body via a detent hinge configured maintain the access door in at least one of the open configuration or the closed configuration.

Embodiment 11: The aerosol delivery device of any one of Embodiments 1 to 10, or any combination thereof, wherein the access door sealingly engages the distal end of the main body in the closed configuration, to for example, substantially prevent aerosol leakage or air ingress.

Embodiment 12: The aerosol delivery device of any one of Embodiments 1 to 11, or any combination thereof, wherein the third aerosol passageway is configured to redirect a vapor path extending through the main body about 180°.

Embodiment 13: The aerosol delivery device of any one of Embodiments 1 to 12, or any combination thereof, further comprising an actuator assembly coupled to the holder and configured to eject the removable cartridge therefrom by, for example, contacting the removable cartridge when loaded within the receiving chamber so as to push the cartridge out of the distal end of the holder.

Embodiment 14: The aerosol delivery device of any one of Embodiments 1 to 13, or any combination thereof, wherein the actuator assembly comprises a slider body slidably disposed within the main body of the holder and configured to slide along a length of the main body in a first direction and a second direction; a slider button disposed on a surface of the slider body and configured to be accessible to a user, for example, via a first protrusion extending from an outer surface of the slider body and extending through an opening in a wall of the main body to provide for moving the slider body in the first and second directions; and a stem extending beyond a distal end of the slider body and configured to engage with the ignitable heat source of the removable cartridge to drive the cartridge at least partially out of the receiving cavity.

Embodiment 15: The aerosol delivery device of any one of Embodiments 1 to 14, or any combination thereof, further comprising a seal assembly disposed within the receiving chamber and configured to removably secure the removable cartridge therein.

Embodiment 16: The aerosol delivery device of any one of Embodiments 1 to 15, or any combination thereof, further comprising the removable cartridge, wherein the cartridge includes a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat thereto and the cartridge is oriented so that the ignitable heat source is disposed between the ignitor contacts.

Embodiment 17: The aerosol delivery device of any one of Embodiments 1 to 16, or any combination thereof, wherein the opening comprises a guard disposed therein and configured to prevent contact with the ignitable heat source when the removable cartridge is loaded within the receiving chamber.

Embodiment 18: The aerosol delivery device of any one of Embodiments 1 to 17, or any combination thereof, wherein the device defines a complex vapor path that extends from the opening in the side wall of the holder, through the removable cartridge, the third aerosol passageway, the first aerosol passageway, and the second aerosol passageway, to deliver an aerosol generated from the removable cartridge to a user.

Embodiment 19: The aerosol delivery device of any one of Embodiments 1 to 18, or any combination thereof, wherein the access door defines a third aerosol passageway and, in an open configuration, the access door provides access to the receiving chamber for loading the removable cartridge therein and, in a closed configuration, fluidly couples the receiving chamber with the first aerosol passageway via the third aerosol passageway.

Embodiment 20: The aerosol delivery device of any one of Embodiments 1 to 19, or any combination thereof, wherein the opening is configured to provide air intake therethrough for mixing with an aerosol generated by the removable cartridge and deliverable to a user via the mouthpiece.

Embodiment 21: The aerosol delivery device of any one of Embodiments 1 to 20, or any combination thereof, wherein the opening is configured to provide a view of the ignitable heat source portion of the cartridge.

Embodiment 22: The aerosol delivery device of any one of Embodiments 1 to 21, or any combination thereof, further comprising a mouthpiece including a first end and a longitudinally opposed second end with a third aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the holder.

Embodiment 23: The aerosol delivery device of any one of Embodiments 1 to 22, or any combination thereof, wherein the actuator assembly comprises a slider body slidably disposed within the main body of the holder and configured to slide along a length of the main body in a first direction and a second direction; a slider button disposed on a surface of the slider body and configured to extend through an opening in a wall of the holder to provide for moving the slider body in the first and second directions; and a stem extending beyond a distal end of the slider body and configured to engage with the ignitable heat source of the removable cartridge to drive the cartridge at least partially out of the receiving chamber.

Embodiment 24: An aerosol delivery device comprising a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source, the main body further defining a first aerosol passageway that extends through at least a portion of the main body; a mouthpiece including a first end and a longitudinally opposed second end with a second aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the holder; an opening defined by the main body and in fluid communication with the receiving chamber and oriented so as substantially align with the ignitable heat source when the removable cartridge is loaded within the receiving chamber; and a third aerosol passageway defined by the distal end of the main body and configured to fluidly couple the receiving chamber and the first aerosol passageway.

Embodiment 25: The aerosol delivery device of the preceding Embodiment, wherein the first, second, and third aerosol passageways define a vapor path extending through the aerosol delivery device and the third aerosol passageway is configured to redirect the vapor path through the main body about 180°.

Embodiment 26: The aerosol delivery device of any one of Embodiments 24 or 25, or any combination thereof, further comprising an access door movably coupled to the distal end of the main body and configured to provide access to the receiving chamber for loading the removable cartridge therein.

Embodiment 27: The aerosol delivery device of any one of Embodiments 24 to 26, or any combination thereof, wherein the access door at least partially defines the third aerosol passageway and, in an open configuration, the access door provides access to the receiving chamber for loading the removable cartridge therein and, in a closed configuration, fluidly couples the receiving chamber with the first aerosol passageway via the third aerosol passageway.

Embodiment 28: The aerosol delivery device of any one of Embodiments 24 to 27, or any combination thereof, wherein the opening is configured to provide air intake therethrough for mixing with an aerosol generated by the removable cartridge and deliverable to a user via the mouthpiece.

Embodiment 29: The aerosol delivery device of any one of Embodiments 24 to 28, or any combination thereof, wherein the opening is configured to provide a view of the ignitable heat source portion of the cartridge.

Embodiment 30: An aerosol delivery device comprising a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source, the main body further defining a first aerosol passageway that extends through at least a portion of the main body; a second aerosol passageway defined by the distal end of the main body and configured to fluidly couple the receiving chamber and the first aerosol passageway; an access door movably coupled to the distal end of the main body, wherein, in an open configuration, the access door provides access to the receiving chamber for loading the removable cartridge therein and, in a closed configuration, secures the cartridge within the receiving chamber; and an actuator assembly coupled to the holder and configured to contact the removable cartridge when loaded within the receiving chamber and eject the cartridge out of the distal end of the holder.

Embodiment 31: The aerosol delivery device of the preceding Embodiment, wherein the first and second aerosol passageways define a vapor path extending through the aerosol delivery device and the second aerosol passageway is configured to redirect the vapor path through the main body about 180°.

Embodiment 32: The aerosol delivery device of any one of Embodiments 30 or 31, or any combination thereof, wherein the access door at least partially defines the second aerosol passageway and, in the closed configuration, fluidly couples the receiving chamber with the first aerosol passageway via the second aerosol passageway.

Embodiment 33: The aerosol delivery device of any one of Embodiments 30 to 32, or any combination thereof, further comprising a mouthpiece including a first end and a longitudinally opposed second end with a third aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the holder.

Embodiment 34: The aerosol delivery device of any one of Embodiments 30 to 33, or any combination thereof, wherein the actuator assembly comprises a slider body slidably disposed within the main body of the holder and configured to slide along a length of the main body in a first direction and a second direction; a slider button disposed on a surface of the slider body and configured to extend through an opening in a wall of the holder to provide for moving the slider body in the first and second directions; and a stem extending beyond a distal end of the slider body and configured to engage with the ignitable heat source of the removable cartridge to drive the cartridge at least partially out of the receiving chamber.

Embodiment 35: The aerosol delivery device of any one of Embodiments 30 to 34, or any combination thereof, further comprising a power source disposed within the main body and a pair of ignitor contacts in electrical communication with the power supply and disposed proximate the opening and configured to engage the ignitable heat source when the removable cartridge is loaded within the receiving chamber.

Embodiment 36: The aerosol delivery device of any one of Embodiments 30 to 35, or any combination thereof, further comprising an ignition switch in electrical communication with the power source and the ignitor contacts and configured to provide power to the contacts when actuated.

Embodiment 37: The aerosol delivery device of any one of Embodiments 30 to 36, or any combination thereof, further comprising a printed circuit board disposed within the holder and in electrical communication with the power source and comprising a controller.

Embodiment 38: The aerosol delivery device of any one of Embodiments 30 to 37, or any combination thereof, wherein the printed circuit board further comprises a charging port and the printed circuit board is oriented within the holder so that the charging port is disposed at one end of the holder.

Embodiment 39: The aerosol delivery device of any one of Embodiments 30 to 38, or any combination thereof, wherein the opening comprises a guard disposed therein and configured to prevent contact with the ignitable heat source when the removable cartridge is loaded within the receiving chamber.

Embodiment 40: The aerosol delivery device of any one of Embodiments 30 to 39, or any combination thereof, further comprising a slide mechanism configured to transition the access door from the closed configuration to the open configuration upon actuation thereof. The slide mechanism comprises a sliding button assembly disposed proximate the distal end of the main body and configured to engage a lip of the access door to transition the door into the open configuration.

Embodiment 41: The aerosol delivery device of any one of Embodiments 30 to 40, or any combination thereof, wherein the access door is coupled to the main body via a detent hinge configured maintain the access door in at least one of the open configuration or the closed configuration.

Embodiment 42: The aerosol delivery device of any one of Embodiments 30 to 41, or any combination thereof, wherein the access door sealingly engages the distal end of the main body in the closed configuration, to for example, substantially prevent aerosol leakage or air ingress.

Embodiment 43: The aerosol delivery device of any one of Embodiments 30 to 42, or any combination thereof, further comprising a seal assembly disposed within the receiving chamber and configured to removably secure the removable cartridge therein.

Embodiment 44: An aerosol delivery device having different consumable loading and ejecting paths, where the device comprises a holder comprising an upper body portion and a lower body portion, each defining a proximal end and a distal end. The lower body portion further defines a receiving chamber disposed in the proximal end thereof and configured to receive a removable cartridge therein and the upper body portion comprises an actuator assembly slidably disposed within the upper body portion and configured to eject the removable cartridge from the lower body portion via the distal end thereof and defining a first aerosol passageway, wherein the upper body portion and the lower body portion are coupled together and configured to be rotatable relative to one another between an open configuration exposing the receiving chamber for loading the removable cartridge and closed configuration where the cartridge may be ejected from the distal end of the lower body portion.

Embodiment 45: An aerosol delivery device having different consumable loading and ejecting paths, where the device comprises a holder comprising an upper body portion and a lower body portion rotatably coupled to the upper body portion and rotatable between an open configuration and a closed configuration, each body portion defining a proximal end and a distal end. The lower body portion further defines a receiving chamber disposed in the proximal end thereof and configured to receive a removable cartridge in the open configuration and the upper body portion comprises a power source disposed therein and defines a first aerosol passageway therethrough. The device further comprises an actuator assembly disposed within the upper body portion and configured to eject the removable cartridge from the lower body portion via the distal end thereof in the closed configuration and a mouthpiece including a first end and a longitudinally opposed second end with a second aerosol passageway extending longitudinally therebetween, wherein the first end of the mouthpiece is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the upper body portion.

Embodiment 46: The aerosol delivery device of any one of Embodiments 44 or 45, or any combination thereof, wherein the actuator assembly comprises a tubular body defining a portion of the first aerosol passageway and configured to slide along a portion of the upper body portion in a first direction and a second direction; a first protrusion extending from an outer surface of the tubular body and configured to extend through an opening in a wall of the upper body portion to provide for moving the tubular body in the first and second directions; and a second protrusion extending from a distal end of the tubular body and configured to engage the removable cartridge so as to advance the removable cartridge through the distal end of the lower body portion when the tubular body is moved in the first or second direction.

Embodiment 47: The aerosol delivery device of any one of Embodiments 44 to 46, or any combination thereof, wherein the actuator further comprises a sealing arrangement for sealingly engaging an internal surface of the upper body portion.

Embodiment 48: The aerosol delivery device of any one of Embodiments 44 to 47, or any combination thereof, further comprising a pair of ignitor contacts coupled to the lower body portion and disposed proximate the distal end thereof, wherein the ignitor contacts are configured to engage with an ignitable heat source portion of the removable cartridge when the removable cartridge is secured within the receiving chamber.

Embodiment 49: The aerosol delivery device of any one of Embodiments 44 to 48, or any combination thereof, wherein the ignitor contacts are in electrical communication with the power source.

Embodiment 50: The aerosol delivery device of any one of Embodiments 44 to 49, or any combination thereof, further comprising a button assembly configured to deliver electrical energy to the ignitable heat source when actuated.

Embodiment 51: The aerosol delivery device of any one of Embodiments 44 to 50, or any combination thereof, wherein the ignitor contacts are movably coupled to the lower body portion and movable between a first position spaced apart from the ignitable heat source and a second position contacting the ignitable heat source.

Embodiment 52: The aerosol delivery device of any one of Embodiments 44 to 51 or any combination thereof, further comprising an ignitor assembly coupled to the holder and configured to move the ignitor contacts into the second position in contact with the ignitable heat source.

Embodiment 53: The aerosol delivery device of any one of Embodiments 44 to 52 or any combination thereof, wherein the ignitor contacts are pivotably coupled to the lower body portion and configured to deflect when contacted by the ignitable heat source portion so as to removably secure the ignitable heat source portion therebetween when the removable cartridge is removably secured within the receiving cavity.

Embodiment 54: The aerosol delivery device of any one of Embodiments 44 to 53, or any combination thereof, further comprising a locking mechanism, such as, for example, a detent, a magnetic engagement, a snap-fit, or similar, disposed on at least one of the lower body portion or the upper body portion and configured to maintain the device in the closed configuration.

Embodiment 55: The aerosol delivery device of any one of Embodiments 44 to 54, or any combination thereof, further comprising a mouthpiece including a first end and a longitudinally opposed second end with a second aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the holder.

Embodiment 56: The aerosol delivery device of any one of Embodiments 44 to 55, or any combination thereof, wherein the mouthpiece is removable.

Embodiment 57: The aerosol delivery device of any one of Embodiments 44 to 56, or any combination thereof, wherein the lower body portion comprises a window disposed therein and configured to provide a view of at least a portion of the removable cartridge.

Embodiment 58: The aerosol delivery device of any one of Embodiments 44 to 57, or any combination thereof, further comprising the removable cartridge, wherein the cartridge includes an ignitable heat source and a substrate portion having an aerosol precursor composition configured to form an aerosol upon application of heat thereto.

Embodiment 59: The aerosol delivery device of any one of Embodiments 44 to 58, or any combination thereof, further comprising a seal assembly disposed within the receiving chamber and configured to removably secure the removable cartridge therein.

Embodiment 60: The aerosol delivery device of any one of Embodiments 44 to 59, or any combination thereof, wherein the lower body further comprises a printed circuit board disposed therein and in electrical communication with the power source and comprising a charging port, wherein the printed circuit board is oriented so that the charging port is disposed at the distal end of the lower body portion.

Embodiment 61: An aerosol delivery device having different consumable loading and ejecting paths, where the device comprises a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge, the main body further defining a first aerosol passageway that extends through at least a portion of the main body, wherein a sidewall of the holder defines an opening therethrough and in communication with the receiving chamber; an access door sealingly coupled to the main body and disposed proximate the opening, where, in an open configuration, the access door is positioned so as to expose the opening and provide access to the receiving chamber for loading the removable cartridge therein and, in a closed configuration, the access door is positioned to cover the opening so as to secure the cartridge in fluid communication with first aerosol passageway; and an actuator assembly coupled to the main body and configured to eject the removable cartridge through the distal end thereof.

Embodiment 62: The aerosol delivery device of the preceding Embodiment further comprising a power source disposed within the main body and a pair of ignitor contacts in electrical communication with the power supply and disposed proximate the distal end of the main body and configured to engage an ignitable heat source portion of the removable cartridge when the removable cartridge is secured within the receiving chamber.

Embodiment 63: The aerosol delivery device of any one of Embodiments 61 or 62, or any combination thereof, wherein the ignitor contacts are pivotably coupled to the main body and configured to deflect when contacted by the ignitable heat source portion so as to removably secure the ignitable heat source portion therebetween when the removable cartridge is removably secured within the receiving cavity.

Embodiment 64: The aerosol delivery device of any one of Embodiments 61 to 63, or any combination thereof, wherein the actuator assembly is configured to eject the removable cartridge by deflecting the ignitor contacts open to release the removable cartridge therefrom. For example, the actuator assembly may include a driver portion (e.g., a body) with an inclined or wedged shape that is oriented so that a leading edge thereof is inserted between and in contact with the ignitor contacts, so that as the driver is advanced, the inclined surfaces thereof push the ignitor contacts outwardly and out of contact with the ignitable heat source portion of the cartridge. The cartridge is then free to fall out of the holder when the distal end is angled downward.

Embodiment 65: The aerosol delivery device of any one of Embodiments 61 to 64, or any combination thereof, further comprising a button assembly configured to deliver electrical energy to the ignitable heat source when actuated.

Embodiment 66: The aerosol delivery device of any one of Embodiments 61 to 65, or any combination thereof, wherein the access door is slidably coupled to the main body and configured to be slid distally into the open configuration. The door may be slidably and sealingly coupled to the main body via a track and rail mechanism. The door could also be coupled to the main body via a hinge or threaded mechanism, with or without a gasket.

Embodiment 67: The aerosol delivery device of any one of Embodiments 61 to 66, or any combination thereof, further comprising a latching mechanism configured to secure the access door in the closed configuration. In some implementations, the latching mechanism may include a magnetic engagement, a threaded interface, a snap-fit, a detent, and/or be spring-loaded into the closed configuration. The door may be flush with an outer surface of the holder when in the closed configuration and may include a raised edge or a knurled (or otherwise textured) surface formed thereon to assist in sliding the door into the open configuration.

Embodiment 68: The aerosol delivery device of any one of Embodiments 61 to 67, or any combination thereof, wherein the holder further comprises a printed circuit board disposed therein and in electrical communication with the power source and comprising a charging port, wherein the printed circuit board is oriented so that the charging port is disposed at the distal end of the main body.

Embodiment 69: The aerosol delivery device of any one of Embodiments 61 to 68, or any combination thereof, further comprising a mouthpiece including a first end and a longitudinally opposed second end with a second aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the holder.

Embodiment 70: An aerosol delivery device comprising a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source therein and a receptacle that extends along at least a portion of the main body and a mouthpiece movably coupled to the main body and including a first end and a longitudinally opposed second end with a first aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the holder. The mouthpiece is configured to translate between an open configuration where the receiving chamber is exposed for loading of the removable cartridge and a closed configuration where the first aerosol passageway is generally aligned with the receiving chamber (e.g., in fluid communication therewith).

Embodiment 71: The aerosol delivery device of the preceding Embodiment further comprising a translating mechanism movably coupled to the main body and at least partially disposed within the receptacle, wherein the translating mechanism is configured to couple the mouthpiece to the holder and bias the mouthpiece into the closed configuration. For example, the translating mechanism and/or the holder may include a spring, an elastomeric member, or similar biasing mechanism configured to apply an outward force on the translating mechanism.

Embodiment 72: The aerosol delivery device of any one of Embodiment 70 or 71, or any combination thereof, wherein the main body receptacle is configured to at least partially receive the translating mechanism and the mouthpiece in the open configuration.

Embodiment 73: The aerosol delivery device of any one of Embodiments 70 to 72, or any combination thereof, wherein the mouthpiece is translated into the receptacle upon application of a force to the translating mechanism. For example, the mouthpiece and translating mechanism are recessed into a cavity of the receptacle that includes a spring or other biasing mechanism.

Embodiment 74: The aerosol delivery device of any one of Embodiments 70 to 73, or any combination thereof, wherein a distal end of the translating mechanism or the second end of the mouthpiece is configured to sealingly engage the receiving chamber in the closed configuration.

Embodiment 75: The aerosol delivery device of any one of Embodiments 70 to 74, or any combination thereof, wherein the mouthpiece is slidably disposed within the main body (e.g., through the translating mechanism) and configured to eject the removable cartridge from the distal end of the main body.

Embodiment 76: The aerosol delivery device of any one of Embodiments 70 to 75, or any combination thereof, wherein the mouthpiece comprises a first enlarged portion disposed at the first end of the mouthpiece and a second elongate portion extending from the enlarged portion to the second end of the mouthpiece.

Embodiment 77: The aerosol delivery device of any one of Embodiments 70 to 76, or any combination thereof, wherein the translating mechanism comprises a channel extending therethrough and configured to allow the elongate portion of the mouthpiece to slidably move in a first direction and a second direction therein and a stop disposed within the channel configured to engage the enlarged portion of the mouthpiece to limit travel of the mouthpiece in the first direction.

Embodiment 78: The aerosol delivery device of any one of Embodiments 70 to 77 or any combination thereof, wherein the stop is configured to prevent the mouthpiece from exiting the distal end of the main body.

Embodiment 79: The aerosol delivery device of any one of Embodiments 70 to 78 or any combination thereof, wherein the holder further comprises an upper body portion and a lower body portion rotatably coupled to the upper body portion and rotatable between the open configuration and the closed configuration, each body portion defining a proximal end and a distal end, wherein the lower body portion further defines the receiving chamber in the proximal end thereof and configured to receive the removable cartridge and the upper body portion further defines the first aerosol passageway extending therethrough.

Embodiment 80: The aerosol delivery device of any one of Embodiments 70 to 79 or any combination thereof, wherein the mouthpiece is removable.

Embodiment 81: The aerosol delivery device of any one of Embodiments 70 to 80, or any combination thereof, further comprising a seal assembly disposed within the receiving chamber and configured to removably secure the removable cartridge therein.

Embodiment 82: The aerosol delivery device of any one of Embodiments 70 to 81, or any combination thereof, further comprising a power source and a printed circuit board disposed within the main body, wherein the printed circuit board is in electrical communication with the power source and comprises a controller.

Embodiment 83: The aerosol delivery device of any one of Embodiments 70 to 82, or any combination thereof, further comprising a pair of actuatable ignitor contacts coupled to the main body and disposed proximate the distal end thereof, wherein the actuatable ignitor contacts are configured to be engaged with the ignitable heat source when the removable cartridge is secured within the receiving chamber.

Embodiment 84: The aerosol delivery device of any one of Embodiments 70 to 83, or any combination thereof, wherein the actuatable ignitor contacts are in electrical communication with the power source.

Embodiment 85: The aerosol delivery device of any one of Embodiments 70 to 84, or any combination thereof, further comprising an actuator (e.g., a button assembly) configured to be engageable with an electrical contact so as to deliver electrical current to the actuatable ignitor contacts when actuated.

Embodiment 86: The aerosol delivery device of any one of Embodiments 70 to 85 or any combination thereof, further comprising a biasing mechanism disposed within the holder and/or the translating mechanism and configured to bias the mouthpiece in the second direction, so as to, for example, position the enlarged portion of the mouthpiece at least partially outside of the holder.

Embodiment 87: An aerosol delivery device comprising a holder comprising an upper body portion and a lower body portion rotatably coupled to the upper body portion and rotatable between an open configuration and a closed configuration, each body portion defining a proximal end and a distal end, wherein the lower body portion further defines a receiving chamber disposed in the proximal end thereof and configured to receive a removable cartridge comprising an ignitable heat source, and the upper body portion further defines a first aerosol passageway extending therethrough; and a mouthpiece including a first end and a longitudinally opposed second end with a second aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is coupled to the proximal end of the upper body portion, wherein, in the open configuration, the receiving chamber is exposed for loading of the removable cartridge and, in the closed configuration, the first aerosol passageway is generally aligned with the receiving chamber (e.g., in fluid communication therewith).

Embodiment 88: An aerosol delivery device comprising a holder comprising an upper body portion and a lower body portion rotatably coupled to the upper body portion and rotatable between an open configuration and a closed configuration, each body portion defining a proximal end and a distal end, wherein the lower body portion further defines a receiving chamber disposed in the proximal end thereof, the receiving chamber configured to receive a removable cartridge comprising an ignitable heat source when in the open configuration; and the upper body portion further defines a first aerosol passageway extending therethrough and comprises a mouthpiece disposed at least partially therein, wherein the first aerosol passageway and the receiving chamber are aligned in the closed configuration so as to pass an aerosol generated from the removable cartridge to a user via the mouthpiece.

Embodiment 89: The aerosol delivery device of any one of Embodiment 87 or 88, or any combination thereof, wherein the first and second aerosol passageways are configured to define a linear vapor path from the distal end of the lower body portion to the first end of the mouthpiece for passing the aerosol generated from the removable cartridge to a user when in the closed configuration.

Embodiment 90: The aerosol delivery device of any one of Embodiments 87 to 89, or any combination thereof, further comprising an actuator assembly slidably disposed within the upper body portion, the actuator configured to eject the removable cartridge from the lower body portion.

Embodiment 91: The aerosol delivery device of any one of Embodiments 87 to 90, or any combination thereof, wherein the actuator assembly is slidably disposed within the first aerosol passageway of the upper body portion.

Embodiment 92: The aerosol delivery device of any one of Embodiments 87 to 91, or any combination thereof, further comprising a power source and a printed circuit board disposed within the upper body portion, wherein the printed circuit board is in electrical communication with the power source and comprises a controller.

Embodiment 93: The aerosol delivery device of any one of Embodiments 87 to 92, or any combination thereof, further comprising a pair of actuatable ignitor contacts coupled to the lower body portion and disposed proximate the distal end thereof, wherein the actuatable ignitor contacts are configured to be engaged with the ignitable heat source when the removable cartridge is secured within the receiving chamber.

Embodiment 94: The aerosol delivery device of any one of Embodiments 87 to 93, or any combination thereof, wherein the actuatable ignitor contacts are in electrical communication with the power source.

Embodiment 95: The aerosol delivery device of any one of Embodiments 87 to 94, or any combination thereof, further comprising an actuator (e.g., button) configured to engage an electrical contact so as to deliver electrical current to the actuatable ignitor contacts when actuated.

Embodiment 96: The aerosol delivery device of any one of Embodiments 87 to 95, or any combination thereof, further comprising a locking mechanism disposed on at least one of the lower body portion or the upper body portion and configured to maintain the device in the closed configuration. Locking mechanisms may include, for example, magnets, hinge friction, a snap fit, a detent, etc.

Embodiment 97: The aerosol delivery device of any one of Embodiments 87 to 96, or any combination thereof, wherein the lower body portion comprises a window disposed therein and configured to provide a view of at least a portion of the removable cartridge.

Embodiment 98: The aerosol delivery device of any one of Embodiments 87 to 97, or any combination thereof, further comprising a seal assembly disposed within the receiving chamber and configured to removably secure the removable cartridge therein.

Embodiment 99: An aerosol delivery device comprising a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source therein; a mouthpiece movably coupled to the main body and including a first end and a longitudinally opposed second end with a first aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the holder so as to provide fluid communication between the receiving chamber and the first aerosol passageway; and a biasing mechanism disposed within the main body and operatively coupled to the mouthpiece. The biasing mechanism is configured to maintain the mouthpiece in a neutral orientation (e.g., in a position for use) and the mouthpiece is actuatable to eject the removable cartridge from the receiving chamber.

Embodiment 100: The aerosol delivery device of the preceding Embodiment, wherein the mouthpiece is actuated via application of a force to the first end of the mouthpiece that is greater than a resistance of the biasing mechanism.

Embodiment 101: The aerosol delivery device of any one of Embodiment 99 or 100, or any combination thereof, wherein the second end of the mouthpiece is configured to sealingly engage with the receiving chamber or the removable cartridge.

Embodiment 102: The aerosol delivery device of any one of Embodiments 99 to 101, or any combination thereof, further comprising a receptacle defined by the holder and extending along at least a portion of the main body and a translating mechanism movably coupled to the main body and at least partially disposed within the receptacle. The translating mechanism is configured to couple the mouthpiece to the holder and move the mouthpiece between an open configuration where the receiving chamber is exposed for loading of the removable cartridge and a closed configuration where the first aerosol passageway is generally aligned with the receiving chamber.

Embodiment 103: The aerosol delivery device of any one of Embodiments 99 to 102, or any combination thereof, wherein the mouthpiece is slidably disposed within the main body (e.g., through the translating mechanism) and configured to eject the removable cartridge from the distal end of the main body.

Embodiment 104: The aerosol delivery device of any one of Embodiments 99 to 103, or any combination thereof, wherein a distal end of the translating mechanism or the second end of the mouthpiece is configured to sealingly engage the receiving chamber in the closed configuration.

Embodiment 105: The aerosol delivery device of any one of Embodiments 99 to 104, or any combination thereof, wherein the mouthpiece comprises a first enlarged portion disposed at the first end of the mouthpiece and a second elongate portion extending from the enlarged portion to the second end of the mouthpiece.

Embodiment 106: The aerosol delivery device of any one of Embodiments 99 to 105, or any combination thereof, wherein the translating mechanism comprises a channel extending therethrough and configured to allow the elongate portion of the mouthpiece to slidably move in a first direction and a second direction therein and a stop disposed within the channel configured to engage the enlarged portion of the mouthpiece to limit travel of the mouthpiece in the first direction.

Embodiment 107: The aerosol delivery device of any one of Embodiments 99 to 106 or any combination thereof, wherein the stop is configured to prevent the mouthpiece from exiting the distal end of the main body.

Embodiment 108: The aerosol delivery device of any one of Embodiments 99 to 107 or any combination thereof, wherein the mouthpiece is removable.

Embodiment 109: The aerosol delivery device of any one of Embodiments 99 to 108, or any combination thereof, further comprising a seal assembly disposed within the receiving chamber and configured to removably secure the removable cartridge therein.

Embodiment 110: The aerosol delivery device of any one of Embodiments 99 to 109, or any combination thereof, further comprising a power source and a printed circuit board disposed within the main body, wherein the printed circuit board is in electrical communication with the power source and comprises a controller.

Embodiment 111: The aerosol delivery device of any one of Embodiments 99 to 110, or any combination thereof, further comprising a pair of actuatable ignitor contacts coupled to the main body and disposed proximate the distal end thereof, wherein the actuatable ignitor contacts are configured to be engaged with the ignitable heat source when the removable cartridge is secured within the receiving chamber.

Embodiment 112: The aerosol delivery device of any one of Embodiments 99 to 111, or any combination thereof, wherein the actuatable ignitor contacts are in electrical communication with the power source.

Embodiment 113: The aerosol delivery device of any one of Embodiments 99 to 112, or any combination thereof, further comprising an actuator (e.g., a button assembly) configured to be engageable with an electrical contact so as to deliver electrical current to the actuatable ignitor contacts when actuated.

Embodiment 114: The aerosol delivery device of any one of Embodiments 99 to 113, or any combination thereof, further comprising a biasing mechanism disposed within the holder and/or the translating mechanism and configured to bias the mouthpiece in the second direction, so as to, for example, position the enlarged portion of the mouthpiece at least partially outside of the holder.

Embodiment 115: The aerosol delivery device of any one of Embodiments 99 to 114, or any combination thereof, further comprising a biasing mechanism disposed within the receptacle and configured to bias the translating mechanism into the closed configuration.

Embodiment 116: The aerosol delivery device of any one of Embodiments 99 to 115, or any combination thereof, wherein the first aerosol passageway and the receiving chamber are configured to define a linear vapor path from the distal end of the main body to the first end of the mouthpiece for passing the aerosol generated from the removable cartridge to a user when in use.

Embodiment 117: The aerosol delivery device of any one of Embodiments 99 to 116, or any combination thereof, wherein the holder comprises a window disposed therein and configured to provide a view of at least a portion of the removable cartridge.

Embodiment 118: The aerosol delivery device of any one of Embodiments 99 to 117, or any combination thereof, wherein a distal end of the translating mechanism is configured to sealingly engage the receiving chamber in the closed configuration.

Embodiment 119: An aerosol delivery device comprising a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source therein and further defining a first aerosol passageway that extends through at least a portion of the main body; a mouthpiece including a first end and a longitudinally opposed second end with a second aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the holder; and an access door pivotably coupled to the distal end of the main body and defining an opening therein, wherein, in an open configuration, the access door provides access to the receiving chamber for loading the removable cartridge therein and, in a closed configuration, secures the removable cartridge in the receiving chamber for ignition thereof. The access door essentially rotates relative to the holder main body. Additionally, the opening in the access door may provide for air ingress to provide air/oxygen to an ignited heat source.

Embodiment 120: The aerosol delivery device of the preceding Embodiment, further comprising a power source disposed within the main body and a pair of ignitor contacts disposed within the access door and in electrical communication with the power source when the access door is in the closed configuration.

Embodiment 121: The aerosol delivery device of any one of Embodiment 119 or 120, or any combination thereof, wherein the ignitor contacts are partially disposed within the opening in the access door and configured to engage the ignitable heat source when a cartridge is disposed within the receiving chamber and the access door is in the closed configuration.

Embodiment 122: The aerosol delivery device of any one of Embodiments 119 to 121, or any combination thereof, further comprising an ignition switch in electrical communication with the power source and the ignitor contacts and configured to provide power to the contacts when actuated.

Embodiment 123: The aerosol delivery device of any one of Embodiments 119 to 122, or any combination thereof, further comprising a first printed circuit board disposed within the holder and in electrical communication with the power source and comprising a controller.

Embodiment 124: The aerosol delivery device of any one of Embodiments 119 to 123, or any combination thereof, wherein the distal end of the main body and the access door each comprise a mating half of an electrical coupling.

Embodiment 125: The aerosol delivery device of any one of Embodiments 119 to 124, or any combination thereof, wherein the distal end of the main body comprises at least one electrical contact in electrical communication with the power source and the access door comprises at least one mating electrical contact in electrical communication with the ignitor contacts, wherein the electrical contacts complete an electrical circuit when the access door is in the closed configuration.

Embodiment 126: The aerosol delivery device of any one of Embodiments 119 to 125, or any combination thereof, wherein at least one of the electrical contacts comprises a pogo pin.

Embodiment 127: The aerosol delivery device of any one of Embodiments 119 to 126, or any combination thereof, wherein the electrical circuit is disrupted when the access door is in the open configuration.

Embodiment 128: The aerosol delivery device of any one of Embodiments 119 to 127, or any combination thereof, wherein the device further comprises a biasing mechanism disposed within the main body and configured to bias the access door into the open and/or closed configuration.

Embodiment 129: The aerosol delivery device of any one of Embodiments 119 to 128, or any combination thereof, wherein the access door is coupled to the main body via a detent hinge configured maintain the access door in at least one of the open configuration or the closed configuration. For example, the door can be “flipped” between configurations and maintained in either configuration via a spring.

Embodiment 130: The aerosol delivery device of any one of Embodiments 119 to 129, or any combination thereof, wherein the access door sealingly engages the distal end of the main body in the closed configuration.

Embodiment 131: The aerosol delivery device of any one of Embodiments 119 to 130, or any combination thereof, further comprising a latching mechanism (e.g., magnetic engagement) configured to secure the access door in the closed configuration.

Embodiment 132: The aerosol delivery device of any one of Embodiments 119 to 131, or any combination thereof, wherein the receiving chamber comprises a biasing mechanism disposed therein, the biasing member configured to maintain the removable cartridge in contact with the ignitor contacts in the closed configuration.

Embodiment 133: The aerosol delivery device of any one of Embodiments 119 to 132, or any combination thereof, further comprising a seal assembly disposed within the receiving chamber and configured to removably secure the removable cartridge therein.

Embodiment 134: The aerosol delivery device of any one of Embodiments 119 to 133, or any combination thereof, wherein the seal assembly comprises the biasing member.

Embodiment 135: The aerosol delivery device of any one of Embodiments 119 to 134, or any combination thereof, further comprising an inner housing disposed within the main body of the holder and configured to secure one or more components therein.

Embodiment 136: The aerosol delivery device of any one of Embodiments 119 to 135, or any combination thereof, wherein the inner housing is configured to receive the power source and the first printed circuit board.

Embodiment 137: The aerosol delivery device of any one of Embodiments 119 to 136, or any combination thereof, wherein the mouthpiece is removable.

Embodiment 138: The aerosol delivery device of any one of Embodiments 119 to 137, or any combination thereof, wherein the aerosol delivery device further comprises a collar disposed between the holder and the mouthpiece. The collar comprises a first end configured to sealingly engage the proximal end of the holder, a second end configured to sealingly engage the second end of the mouthpiece, and defines a third aerosol passageway therethrough configured to fluidly couple the first and second aerosol passageways.

Embodiment 139: The aerosol delivery device of any one of Embodiments 119 to 138, or any combination thereof, wherein the collar further comprises a base portion defining an opening in fluid communication with the third aerosol passageway and having a first sealing mechanism disposed about an exterior surface thereof, the base portion sized and shaped to engage an opening in the proximal end of the holder; and a body portion defining an opening in fluid communication with the third aerosol passageway and having a second sealing mechanism disposed about an exterior surface thereof, the body portion sized and shaped to engage a recess disposed within the second end of the mouthpiece.

Embodiment 140: The aerosol delivery device of any one of Embodiments 119 to 139, or any combination thereof, wherein the base portion is coupled to the holder via at least one fastener.

Embodiment 141: The aerosol delivery device of any one of Embodiments 119 to 140, or any combination thereof, further comprising an inner housing disposed within the main body of the holder and defining at least a portion of the first aerosol passageway and the base portion of the collar includes a stem extending distally therefrom and configured to engage the at least a portion of the first aerosol passageway in the inner housing.

Embodiment 142: The aerosol delivery device of any one of Embodiments 119 to 141, or any combination thereof, further comprising a second printed circuit board disposed within the holder and comprising a charging port, wherein the second printed circuit board is oriented within the holder so that the charging port is disposed at one end of the holder.

Embodiment 143: The aerosol delivery device of any one of Embodiments 119 to 142, or any combination thereof, wherein the opening is configured to provide air/oxygen to the ignited heat source. In some implementations, the air/oxygen may travel through the heat source and/or the air/oxygen may mix with an aerosol generated by the removable cartridge and delivered to a user via the mouthpiece.

Embodiment 144: The aerosol delivery device of any one of Embodiments 119 to 143, or any combination thereof, wherein the opening is configured to provide a view of the ignitable heat source portion of the cartridge.

Embodiment 145: The aerosol delivery device of any one of Embodiments 119 to 144, or any combination thereof, wherein the opening comprises a guard disposed therein and configured to prevent contact with the ignitable heat source when the removable cartridge is loaded within the receiving chamber.

Embodiment 146: An aerosol delivery device comprising a holder having a main body defining a proximal end and a distal end, where the main body further defines a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source therein and a first aerosol passageway that extends through at least a portion of the main body and a removable mouthpiece that comprises a first portion defined by a first end and a longitudinally opposed second end and a second portion that extends from the longitudinally opposed second end, wherein the first and second portions define a second aerosol passageway extending therethrough, the first end of the first portion is configured to engage with a user's mouth, the second end of the first portion is configured to engage with the proximal end of the holder, and the second portion is configured to extend within the holder.

Embodiment 147: The aerosol delivery device of the preceding Embodiment, wherein the second end of the first portion is configured to engage the opening in the proximal end of the holder via at least one of complementary-threaded surfaces for a screw-type engagement, a press-fit engagement, a snap-fit engagement, or a magnetic engagement.

Embodiment 148: The aerosol delivery device of any one of Embodiments 146 or 147, or any combination thereof, wherein the second portion of the mouthpiece is sealingly engaged with the first aerosol passageway in the holder.

Embodiment 149: The aerosol delivery device of any one of Embodiments 146 to 148, or any combination thereof, wherein the second portion of the mouthpiece includes a sealing mechanism disposed about an exterior surface thereof.

Embodiment 150: The aerosol delivery device of any one of Embodiments 146 to 149, or any combination thereof, wherein the sealing mechanism comprises an O-ring disposed within a groove defined by the exterior surface of the second portion of the mouthpiece.

Embodiment 151: The aerosol delivery device of any one of Embodiments 146 to 150, or any combination thereof further comprising an actuator assembly at least partially disposed within the main body of the holder and configured to eject the removable cartridge therefrom.

Embodiment 152: The aerosol delivery device of any one of Embodiments 146 to 151, or any combination thereof, wherein the actuator assembly comprises a sliding body that defines at least a portion of the first aerosol passageway and the second portion of the mouthpiece is slidably disposed within the sliding body and in fluid communication with the at least a portion of the first aerosol passageway in the sliding body.

Embodiment 153: The aerosol delivery device of any one of Embodiments 146 to 152, or any combination thereof further comprising an inner housing disposed within the main body of the holder and comprising a first retention structure disposed on a proximal end thereof, wherein the second end of the first portion of the mouthpiece defines a mating retention structure (e.g., a gap or groove disposed about the inner perimeter of the second end) configured to engage the retention structure on the inner housing. In some implementations, the inner housing may include a second retention structure configured to mate with the holder and secure the inner housing therein or the first retention structure may be disposed on the proximal end of the holder.

Embodiment 154: The aerosol delivery device of any one of Embodiments 146 to 153, or any combination thereof, wherein a central axis of the second portion of the mouthpiece is offset from a central axis of the first portion of the mouthpiece.

Embodiment 155: An aerosol delivery device comprising a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source therein and a first aerosol passageway that extends through at least a portion of the main body and a removable mouthpiece comprising a hollow body including a first end and a longitudinally opposed second end with a stem disposed within the hollow body and extending from the first end to the second end, the stem defining a second aerosol passageway extending therethrough, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the holder.

Embodiment 156: The aerosol delivery device of the preceding Embodiment, wherein the longitudinally opposed second end is configured to engage an opening in the proximal end of the holder via at least one of complementary-threaded surfaces for a screw-type engagement, a press-fit engagement, a snap-fit engagement, or a magnetic engagement.

Embodiment 157: The aerosol delivery device of any one of Embodiments 155 or 156, or any combination thereof, wherein the stem is sealingly engaged with the first aerosol passageway in the holder.

Embodiment 158: The aerosol delivery device of any one of Embodiments 155 to 157, or any combination thereof, wherein the stem includes a sealing mechanism disposed about an exterior surface thereof.

Embodiment 159: The aerosol delivery device of any one of Embodiments 155 to 158, or any combination thereof further comprising an inner housing disposed within the main body of the holder and defining at least a portion of the first aerosol passageway, wherein the stem is partially disposed within the inner housing and in fluid communication with the at least a portion of the first aerosol passageway in the inner housing.

Embodiment 160: The aerosol delivery device of any one of Embodiments 155 to 159, or any combination thereof, wherein the sealing mechanism comprises an O-ring disposed within a groove defined by the exterior surface of the stem or a substantially air-tight fit between the stem and the inner housing.

Embodiment 161: The aerosol delivery device of any one of Embodiments 155 to 160, or any combination thereof further comprising an inner housing disposed within the main body of the holder and comprising a retention structure disposed on a proximal end thereof, wherein the longitudinally opposed second end of the mouthpiece defines a mating retention structure configured to engage the retention structure on the inner housing.

Embodiment 162: The aerosol delivery device of any one of Embodiments 155 to 161, or any combination thereof, wherein the mouthpiece further comprises an insert removably disposed within a recess formed within the first end of the mouthpiece.

Embodiment 163: The aerosol delivery device of any one of Embodiments 155 to 162, or any combination thereof, wherein the insert is configured to reduce an aerosol outlet in the mouthpiece.

Embodiment 164: The aerosol delivery device of any one of Embodiments 155 to 163, or any combination thereof, wherein a central axis of the stem is offset from a central axis of the mouthpiece.

Embodiment 165: An aerosol delivery device including a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source therein, and a removable mouthpiece comprising an elongate body portion defined by a first end and a longitudinally opposed second end and defining an aerosol passageway extending therethrough, a first retention mechanism disposed about an exterior surface of the elongate body portion, the first retention mechanism configured to removably secure the second end of the mouthpiece within the holder, and a second retention mechanism disposed within a receptacle defined by the second end of the elongate body member, the second retention mechanism configured to removably secure a portion of the cartridge therein, wherein the first end of the mouthpiece is configured to engage with a user's mouth. In some implementations, the first retention mechanism is located proximate the first end of the elongate body portion.

Embodiment 166: The aerosol delivery device of the preceding Embodiment further comprising an inner housing disposed within the main body of the holder and defining a passageway therethrough configured to receive a portion of the mouthpiece therein.

Embodiment 167: The aerosol delivery device of any one of Embodiments 165 or 166, or any combination thereof further comprising a pair of ignitor contacts disposed within the holder and proximate the distal end thereof, wherein the contacts are configured to receive an ignitable heat source portion of the cartridge therebetween.

Embodiment 168: The aerosol delivery device of any one of Embodiments 165 to 167, or any combination thereof, wherein the inner housing comprises a stop configured to configured to limit insertion of the mouthpiece so as to operatively engage the ignitable heat source with the ignitor contacts.

Embodiment 169: The aerosol delivery device of any one of Embodiments 165 to 168, or any combination thereof, wherein the first retention mechanism is configured to sealingly engage with the passageway in the inner housing.

Embodiment 170: The aerosol delivery device of any one of Embodiments 165 to 169, or any combination thereof, wherein the first retention mechanism includes an elastomeric seal disposed about an exterior surface thereof and configured to frictionally engage with the inner housing passageway.

Embodiment 171: The aerosol delivery device of any one of Embodiments 165 to 170, or any combination thereof, wherein the second retention mechanism is configured to sealingly engage with a substrate portion of the cartridge.

Embodiment 172: The aerosol delivery device of any one of Embodiments 165 to 171, or any combination thereof, wherein the second retention mechanism includes an elastomeric seal disposed about an interior surface thereof and configured to frictionally engage with the cartridge.

Embodiment 173: The aerosol delivery device of any one of Embodiments 165 to 172, or any combination thereof further comprising an ignitor push button configured to activate the ignitor contacts thereby igniting the heat source when pressed by a user.

Embodiment 174: The aerosol delivery device of any one of Embodiments 165 to 173, or any combination thereof, wherein the ignitor contacts will be deactivated when the ignitor push button is released.

Embodiment 175: The aerosol delivery device of any one of Embodiments 165 to 174, or any combination thereof, wherein the ignitor contacts will be deactivated after a set time (e.g., about 2 to 60 seconds, about 5 to 30 seconds, or about 20 seconds), either after the ignitor push button is activated or after it is released.

Embodiment 176: An aerosol delivery device including a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source therein, and a removable mouthpiece configured to engage the proximal end of the holder. The mouthpiece comprises a first portion comprising an elongate body defined by a first end and a longitudinally opposed second end and defining a passageway extending therethrough; a second portion defined by a first end and a longitudinally opposed second end and defining a first aerosol passageway therethrough, wherein the first end of the second portion is configured to engage with a user's mouth and the second end is partially disposed within the passageway of the first portion of the mouthpiece proximate the first end of the first portion; a slider body defined by a first end and a longitudinally opposed second end and defining a second aerosol passageway therethrough, wherein the slider body is slidably disposed within the first portion of the mouthpiece and the first end of the slider body is coupled to the second end of the second portion of the mouthpiece and the second end of the slider body is configured to engage the removable cartridge; an inner tubular body defined by a first end and a longitudinally opposed second end and defining a receptacle comprising a first biasing mechanism disposed therein, the receptacle configured to at least partially receive the slider body, the slider body slidably coupled to the inner tubular body, wherein the second end of the inner tubular body is configured to engage the first portion of the mouthpiece proximate the second end of the first portion and the biasing mechanism is configured to maintain the slider body in a loading configuration; and an outlet guide coupled to the second end of the first portion of the mouthpiece and partially received within the second end of the inner tubular body, wherein the outlet guide defines a cavity configured to sealingly engage and removably secure the removable cartridge therein. The slider body may be configured to slide along a length of the first portion of the mouthpiece in a first direction and a second direction.

Embodiment 177: The aerosol delivery device of the preceding Embodiment, wherein the holder further comprises an inner housing disposed within the main body of the holder and defining one or more receptacles therein, an outer tubular body disposed within a first one of the receptacles and defining an interior cavity configured to slidably receive the mouthpiece therein; a first end cap coupled to proximal end of the holder and defining a first opening in communication with the interior cavity of the outer tubular body, the first end cap configured to secure at least one of the inner housing or the outer tubular body within the holder; and a second end cap coupled to the distal end of the holder and defining a second opening in communication with the interior cavity of the outer tubular body, the second end cap configured to secure at least one of the inner housing or the outer tubular body within the holder.

Embodiment 178: The aerosol delivery device of any one of Embodiments 176 or 177, or any combination thereof, wherein the holder comprises a retention mechanism configured to movably couple the mouthpiece to the holder, such as, for example, magnetic engagement or a threaded interface.

Embodiment 179: The aerosol delivery device of any one of Embodiments 176 to 178, or any combination thereof, wherein the holder further comprises a pair of ignitor contacts disposed within the receiving chamber proximate the distal end of the holder and a second biasing mechanism disposed within the main body and configured to engage a distal end of the mouthpiece, wherein the mouthpiece is slidably disposed within the main body and the second biasing mechanism is configured to position an ignitable heat source portion of the cartridge away from the ignitor contacts.

Embodiment 180: The aerosol delivery device of any one of Embodiments 176 to 179, or any combination thereof, wherein the second biasing mechanism comprises a return spring and a collar slidably disposed within the outer tubular body, a distal end of the collar configured to engage the return spring.

Embodiment 181: The aerosol delivery device of any one of Embodiments 176 to 180, or any combination thereof, wherein the first biasing mechanism comprises an ejection spring and the ejection spring has a greater spring force than the return spring. In some cases, this implementation will prevent accidental ejection of the cartridge as the second biasing mechanism will be actuated prior to the first biasing mechanism due to the difference in spring forces.

Embodiment 182: The aerosol delivery device of any one of Embodiments 176 to 181, or any combination thereof, wherein the second end cap further comprises a standoff extending into the inner housing and partially defining the receiving chamber.

Embodiment 183: The aerosol delivery device of any one of Embodiments 176 to 182, or any combination thereof, wherein the standoff comprises a pair of opposing slots configured to secure the ignitor contacts therein so as to be engageable with the ignitable heat source, for example, when the mouthpiece is pressed.

Embodiment 184: The aerosol delivery device of any one of Embodiments 176 to 183, or any combination thereof further comprising a power source disposed within the inner housing, a printed circuit board disposed within the inner housing and in electrical communication with the ignitor contacts, and a switch in electrical communication with the power source and the printed circuit board and configured to electrically couple the power source to the ignitor contacts.

Embodiment 185: The aerosol delivery device of any one of Embodiments 176 to 184, or any combination thereof, wherein the ignitable heat source portion of the cartridge bridges the ignitor contacts upon application of a force to the mouthpiece to complete an electrical circuit.

Embodiment 186: The aerosol delivery device of any one of Embodiments 176 to 185, or any combination thereof, wherein the printed circuit board further comprises a charging port and the printed circuit board is oriented within the inner housing so that the charging port is disposed at the distal end of the holder.

Embodiment 187: The aerosol delivery device of any one of Embodiments 176 to 186, or any combination thereof, wherein the second end of the slider body comprises a stem configured to engage with and eject the removable cartridge upon application of a force to the second portion of the mouthpiece. After removal of the force, the first biasing mechanism returns to its neutral position (e.g., loading orientation).

Embodiment 188: The aerosol delivery device of any one of Embodiments 176 to 187, or any combination thereof, wherein the second end of the second portion of the mouthpiece is configured to engage the first end of the slider body via at least one of complementary-threaded surfaces for a screw-type engagement, a press-fit engagement, a snap-fit engagement, or a magnetic engagement.

Embodiment 189: The aerosol delivery device of any one of Embodiments 176 to 188, or any combination thereof, wherein the second end of the inner tubular body is configured to engage an inner surface of the first portion of the mouthpiece via at least one of complementary-threaded surfaces for a screw-type engagement, a press-fit engagement, a snap-fit engagement, or a magnetic engagement.

Embodiment 190: The aerosol delivery device of any one of Embodiments 176 to 189, or any combination thereof, wherein the outlet guide is configured to engage the second end of the first portion of the mouthpiece via at least one of complementary-threaded surfaces for a screw-type engagement, a press-fit engagement, a snap-fit engagement, or a magnetic engagement.

Embodiment 191: The aerosol delivery device of any one of Embodiments 1 to 190, or any combination thereof further comprising the removable cartridge, wherein the cartridge includes a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat thereto.

Embodiment 192: The aerosol delivery device of any one of Embodiments 1 to 191, or any combination thereof, wherein the holder comprises a window disposed therein, the window configured to provide a view of at least a portion of the removable cartridge.

These and other features, aspects, and advantages of the disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below. The invention includes any combination of two, three, four, or more of the above-noted embodiments as well as combinations of any two, three, four, or more features or elements set forth in this disclosure, regardless of whether such features or elements are expressly combined in a specific embodiment description herein. This disclosure is intended to be read holistically such that any separable features or elements of the disclosed invention, in any of its various aspects and embodiments, should be viewed as intended to be combinable unless the context clearly dictates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described the disclosure in the foregoing general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIGS. 1A and 1B illustrate a perspective view and a cross-sectional perspective view, respectively, of an aerosol delivery device comprising a reverse consumable loading configuration, according to one implementation of the present disclosure;

FIG. 1C illustrates an enlarged, partial cross-sectional view of an alternative distal end of the aerosol delivery device of FIG. 1A.

FIG. 2 illustrates an exploded perspective view of the aerosol delivery device of FIG. 1A, according to one implementation of the present disclosure;

FIGS. 3A-3C illustrate a series of cross-sectional side views of the aerosol delivery device of FIG. 1A in various states of operation, according to one implementation of the present disclosure;

FIGS. 4A-4E illustrate a series of perspective end views of the aerosol delivery device of FIG. 1A in various states of loading, according to one implementation of the present disclosure;

FIG. 5A illustrates a pictorial perspective view of the aerosol delivery device of FIG. 1A in a loaded configuration and the static ignitor contacts disposed therein, according to one implementation of the present disclosure;

FIG. 5B illustrates an enlarged perspective view of a portion of the aerosol delivery device of FIG. 5A, according to one implementation of the present disclosure;

FIG. 6 illustrates a cross-sectional perspective view of the aerosol delivery device of FIG. 1A in a loaded configuration with the vapor path defined therethrough, according to one implementation of the present disclosure;

FIG. 7A illustrates a cross-sectional perspective view of the aerosol delivery device of FIG. 1A during ejection of the consumable, according to one implementation of the present disclosure;

FIG. 7B illustrates an enlarged perspective view of a portion of the aerosol delivery device of FIG. 7A, according to one implementation of the present disclosure;

FIGS. 8A and 8B illustrate a perspective view and a cross-sectional perspective view, respectively, of an aerosol delivery device comprising different consumable loading and ejecting paths, according to one implementation of the present disclosure;

FIG. 9 illustrates an exploded perspective view of the aerosol delivery device of FIG. 8A, according to one implementation of the present disclosure;

FIGS. 10A-10E illustrate a series of perspective side views of the aerosol delivery device of FIG. 8A highlighting the loading of the consumable, according to one implementation of the present disclosure;

FIG. 11A illustrates a cross-sectional perspective view of the device of FIG. 8A in a lighting configuration, according to one implementation of the present disclosure;

FIGS. 11B and 11C illustrate two enlarged perspective end views of a cartridge end of the aerosol delivery device of FIG. 11A, according to one implementation of the present disclosure;

FIGS. 12A and 12B illustrate two cross-sectional perspective views of the device of FIG. 8A highlighting the ejection of the consumable, according to one implementation of the present disclosure;

FIGS. 13A-13C illustrate two perspective views and a cross-sectional perspective view, respectively, of an alternative aerosol delivery device comprising a translating mouthpiece for consumable loading, according to one implementation of the present disclosure;

FIG. 14 illustrates a cross-sectional perspective view of the aerosol delivery device of FIG. 13A during use, according to one implementation of the present disclosure;

FIG. 15 illustrates an exploded perspective view of the aerosol delivery device of FIG. 6A, according to one implementation of the present disclosure;

FIGS. 16A-16D illustrate a series of perspective side views of the aerosol delivery device of FIG. 13A highlighting the loading of the consumable, according to one implementation of the present disclosure;

FIGS. 17A and 17B illustrate two cross-sectional perspective side views of the aerosol delivery device of FIG. 13A highlighting the ejection of the consumable, according to one implementation of the present disclosure;

FIGS. 18A-18C illustrate a series of enlarged perspective end views of a cartridge end of the aerosol delivery device of FIG. 13A, according to one implementation of the present disclosure;

FIGS. 19A and 19B illustrate a perspective view and a cross-sectional perspective view, respectively, of another alternative aerosol delivery device comprising a rotating bottom door for loading and securing a cartridge within the device, according to one implementation of the present disclosure;

FIG. 20 illustrates an exploded perspective view of the aerosol delivery device of FIG. 19A, according to one implementation of the present disclosure;

FIGS. 21A-21C illustrate a series of cross-sectional side views of the aerosol delivery device of FIG. 19A in various states of operation, according to one implementation of the present disclosure;

FIG. 22 illustrates a perspective end view of the aerosol delivery device of FIG. 19A, according to one implementation of the present disclosure;

FIGS. 23A and 23B illustrate two perspective end views of the aerosol delivery device of FIG. 1A in a loading configuration, according to one implementation of the present disclosure;

FIG. 24 illustrates a perspective view of the aerosol delivery device of FIG. 19A in an ejecting configuration, according to one implementation of the present disclosure;

FIGS. 25A and 25B illustrate a perspective view and a cross-sectional side view, respectively, of another aerosol delivery device comprising different consumable loading and ejecting paths, according to one implementation of the present disclosure;

FIG. 26 illustrates an exploded perspective view of the aerosol delivery device of FIG. 25A, according to one implementation of the present disclosure;

FIGS. 27A and 27B illustrate two perspective views of the aerosol delivery device of FIG. 25A in various states of operation, according to one implementation of the present disclosure;

FIGS. 28A and 28B illustrate a perspective view and a cross-sectional side view, respectively, of an alternative aerosol delivery device comprising a removable mouthpiece configured for loading and removing a removable cartridge from the device, according to one implementation of the present disclosure;

FIG. 29 illustrates an exploded view of the aerosol delivery device of FIG. 28A, according to one implementation of the present disclosure;

FIG. 30 illustrates an enlarged, partial cross-sectional view of the mouthpiece end of the aerosol delivery device of FIG. 28A, according to one implementation of the present disclosure;

FIG. 31 illustrates an enlarged, partial cross-sectional view of the mouthpiece of the aerosol delivery device of FIG. 28A engaged with a removable cartridge, according to one implementation of the present disclosure;

FIGS. 32A-32C illustrate a series of perspective views of a removable mouthpiece for use in the aerosol delivery device of FIG. 28A in various states of operation, according to one implementation of the present disclosure;

FIGS. 33 and 34 illustrate a front view and a side view, respectively, of an alternative aerosol delivery device comprising a removable mouthpiece and a removable cartridge, according to one implementation of the present disclosure;

FIG. 35A illustrates a partially exploded perspective view of the aerosol delivery device of FIG. 33, according to one implementation of the present disclosure;

FIG. 35B illustrates an enlarged and more detailed view of the distal end of the aerosol delivery device of FIG. 35A, according to one implementation of the present disclosure;

FIG. 36 illustrates an exploded view of a mouthpiece portion of the aerosol delivery device of FIG. 33, according to one implementation of the present disclosure;

FIGS. 37A-37C illustrate a series of perspective views of the mouthpiece portion of the aerosol delivery device of FIG. 33 in various states of operation, according to one implementation of the present disclosure;

FIG. 38 illustrates an exploded view of a holder portion of the aerosol delivery device of FIG. 33, according to one implementation of the present disclosure;

FIGS. 39A-39C illustrate a series of perspective views of the aerosol delivery device of FIG. 33 in various states of operation, according to one implementation of the present disclosure;

FIG. 40 illustrates a perspective view of a removable cartridge, according to one implementation of the present disclosure; and

FIG. 41 illustrates a longitudinal cross-section view of a removable cartridge, according to one implementation of the present disclosure.

DETAILED DESCRIPTION

Some implementations of the present disclosure will now be described more fully hereinafter with reference to the accompanying figures, in which some, but not all implementations of the disclosure are shown. Indeed, various implementations of the disclosure may be embodied in many different forms and should not be construed as limited to the implementations set forth herein; rather, these example implementations are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Like reference numerals refer to like elements throughout.

Unless specified otherwise or clear from context, references to first, second or the like should not be construed to imply a particular order. A feature described as being above another feature (unless specified otherwise or clear from context) may instead be below, and vice versa; and similarly, features described as being to the left of another feature else may instead be to the right, and vice versa. Also, while reference may be made herein to quantitative measures, values, geometric relationships or the like, unless otherwise stated, any one or more if not all of these may be absolute or approximate to account for acceptable variations that may occur, such as those due to engineering tolerances or the like.

As used herein, unless specified otherwise or clear from context, the “or” of a set of operands is the “inclusive or” and thereby true if and only if one or more of the operands is true, as opposed to the “exclusive or” which is false when all of the operands are true. Thus, for example, “[A] or [B]” is true if [A] is true, or if [B] is true, or if both [A] and [B] are true. Further, the articles “a” and “an” mean “one or more,” unless specified otherwise or clear from context to be directed to a singular form. Furthermore, it should be understood that unless otherwise specified, the terms “data,” “content,” “digital content,” “information,” and similar terms may be at times used interchangeably. Additionally, where multiples of the same components are described, the multiples may be referred to individually (e.g., ##a, ##b, ##c, etc.) or collectively (##).

The present disclosure provides descriptions of articles (and the assembly and/or manufacture thereof) in which a material is heated (preferably without combusting the material to any significant degree) to form an aerosol and/or an inhalable substance; such articles most preferably being sufficiently compact to be considered “hand-held” devices. In some aspects, the articles are characterized as smoking articles. As used herein, the term “smoking article” is intended to mean an article and/or device that provides many of the sensations (e.g., inhalation and exhalation rituals, types of tastes or flavors, organoleptic effects, physical feel, use rituals, visual cues such as those provided by visible aerosol, and the like) of smoking a cigarette, cigar, or pipe, without any substantial degree of combustion of any component of that article and/or device. As used herein, the term “smoking article” does not necessarily mean that, in operation, the article or device produces smoke in the sense of an aerosol resulting from by-products of combustion or pyrolysis of tobacco, but rather, that the article or device yields vapors (including vapors within aerosols that are considered to be visible aerosols that might be considered to be described as smoke-like) resulting from volatilization or vaporization of certain components, elements, and/or the like of the article and/or device. In some aspects, articles or devices characterized as smoking articles incorporate tobacco and/or components derived from tobacco.

As noted, aerosol delivery devices may provide many of the sensations (e.g., inhalation and exhalation rituals, types of tastes or flavors, organoleptic effects, physical feel, use rituals, visual cues such as those provided by visible aerosol, and the like) of smoking a cigarette, cigar or pipe that is employed by lighting and burning tobacco (and hence inhaling tobacco smoke), without any substantial degree of combustion of any component thereof. For example, the user of an aerosol delivery device in accordance with some example implementations of the present disclosure can hold and use that device much like a smoker employs a traditional type of smoking article, draw on one end of that piece for inhalation of aerosol produced by that piece, take or draw puffs at selected intervals of time, and the like.

Articles or devices of the present disclosure are also characterized as being vapor-producing articles, aerosol delivery articles, or medicament delivery articles. Thus, such articles or devices are adaptable so as to provide one or more substances in an inhalable form or state. For example, inhalable substances are substantially in the form of a vapor (e.g., a substance that is in the gas phase at a temperature lower than its critical point). Alternatively, inhalable substances are in the form of an aerosol (e.g., a suspension of fine solid particles or liquid droplets in a gas). For purposes of simplicity, the term “aerosol” as used herein is meant to include vapors, gases, and aerosols of a form or type suitable for human inhalation, whether or not visible, and whether or not of a form that might be considered to be smoke-like. In some implementations, the terms “vapor” and “aerosol” may be interchangeable. Thus, for simplicity, the terms “vapor” and “aerosol” as used to describe the disclosure are understood to be interchangeable unless stated otherwise.

Examples of suitable vapor-producing articles, aerosol delivery articles, or medicament delivery articles include vapor products, heat-not-burn products, hybrid products and the like. Vapor products are commonly known as “electronic cigarettes,” “e-cigarettes” or electronic nicotine delivery systems (ENDS), although the aerosol-generating material need not include nicotine. Many vapor products are designed to heat a liquid material to generate an aerosol. Other vapor products are designed to break up an aerosol-generating material into an aerosol without heating, or with only secondary heating. Heat-not-burn products include tobacco heating products and carbon-tipped tobacco heating products, and many are designed to heat a solid material to generate an aerosol without combusting the material.

Hybrid products use a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, semi-solid, liquid, or gel. Some hybrid products are similar to vapor products except that the aerosol generated from a liquid or gel aerosol-generating material passes through a second material (such as tobacco) to pick up additional constituents before reaching the user. In some example implementations, the hybrid system includes a liquid or gel aerosol-generating material, and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

In use, smoking articles of the present disclosure are subjected to many of the physical actions of an individual in using a traditional type of smoking article (e.g., a cigarette, cigar, or pipe that is employed by lighting with a flame and used by inhaling tobacco that is subsequently burned and/or combusted). For example, the user of a smoking article of the present disclosure holds that article much like a traditional type of smoking article, draws on one end of that article for inhalation of an aerosol produced by that article, and takes puffs at selected intervals of time.

While the systems are generally described herein in terms of implementations associated with smoking articles such as so-called “tobacco heating products,” it should be understood that the mechanisms, components, features, and methods may be embodied in many different forms and associated with a variety of articles. For example, the description provided herein may be employed in conjunction with implementations of traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heat-not-burn cigarettes, and related packaging for any of the products disclosed herein. Accordingly, it should be understood that the description of the mechanisms, components, features, and methods disclosed herein are discussed in terms of implementations relating to aerosol delivery devices by way of example only, and may be embodied and used in various other products and methods.

Aerosol delivery devices of the present disclosure generally include a number of components provided within an outer body or shell, which may be referred to as a housing or a holder. The overall design of the outer body or shell can vary, and the format or configuration of the outer body that can define the overall size and shape of the aerosol delivery device can vary. In some example implementations, an elongated body resembling the shape of a cigarette or cigar can be formed from a single, unitary housing or the elongated housing can be formed of two or more separable bodies. For example, an aerosol delivery device can comprise an elongated shell or body that can be substantially tubular in shape and, as such, resemble the shape of a conventional cigarette or cigar. In another example, an aerosol delivery device may be substantially rectangular or have a substantially rectangular cuboid shape. In one example, all of the components of the aerosol delivery device are contained within one housing. Alternatively, an aerosol delivery device can comprise two or more housings that are joined and are separable. For example, an aerosol delivery device can possess one portion comprising a housing containing one or more reusable components (e.g., an accumulator such as a rechargeable battery and/or rechargeable super-capacitor, and various electronics for controlling the operation of that article), and removably coupleable thereto, another second portion (e.g., a mouthpiece) and/or a disposable component (e.g., a disposable flavor-containing cartridge containing aerosol precursor material, flavorant, etc.). More specific formats, configurations and arrangements of components within the single housing type of unit or within a multi-piece separable housing type of unit will be evident in light of the further disclosure provided herein. Additionally, various aerosol delivery device designs and component arrangements can be appreciated upon consideration of the commercially available electronic aerosol delivery devices.

As will be discussed in more detail below, holders of aerosol delivery devices of the present disclosure may comprise some combination of a power source (e.g., an electrical power source), at least one control component (e.g., means for translating, controlling, regulating and ceasing power, such as by controlling electrical current flow from the power source to other components of the article—e.g., a microprocessor, individually or as part of a microcontroller, a printed circuit board (PCB) that includes a microprocessor and/or microcontroller, etc.), a lighter portion configured to ignite a heat source and/or substrate material of a cartridge, and a receiving chamber. Such holders may be configured to accept one or more substrate cartridges that include a substrate material capable of yielding an aerosol upon application of sufficient heat. In some implementations, the holder may include a mouthpiece portion configured to allow drawing upon the holder for aerosol inhalation (e.g., a defined airflow path through the holder such that aerosol generated can be withdrawn therefrom upon draw).

In various aspects, the heat source of a cartridge may be capable of generating heat to aerosolize a substrate material of the cartridge that comprises, for example, an extruded structure and/or substrate, a substrate material associated with an aerosol precursor composition, tobacco and/or a tobacco related material, such as a material that is found naturally in tobacco that is isolated directly from the tobacco or synthetically prepared, in a solid or liquid form (e.g., beads, sheets, shreds, a wrap), or the like. As will be described in more detail below, in some implementations, an extruded structure may comprise tobacco products or a composite of tobacco with other materials such as, for example, ceramic powder. In other implementations, a tobacco extract/slurry may be loaded into porous ceramic beads. Other implementations may use non-tobacco products. In some implementations aerosol precursor composition-loaded porous beads/powders (ceramics) may be used. In other implementations, rods/cylinders made of extruded slurry of ceramic powder and aerosol precursor composition may be used.

In some implementations, the substrate material may comprise a liquid including an aerosol precursor composition and/or a gel including an aerosol precursor composition. Some examples of liquid compositions can be found in U.S. Pat. Pub. No. US 2020/0113239 to Aller et al., which is incorporated herein by reference in its entirety. As noted above, in various implementations, one or more of the substrate materials may have an aerosol precursor composition associated therewith. For example, in some implementations the aerosol precursor composition may comprise one or more different components, such as polyhydric alcohol (e.g., glycerin, propylene glycol, or a mixture thereof). Representative types of further aerosol precursor compositions are set forth in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al.; U.S. Pat. No. 5,101,839 to Jakob et al.; PCT WO 98/57556 to Biggs et al.; and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988); the disclosures of which are incorporated herein by reference. In some aspects, a substrate material may produce a visible aerosol upon the application of sufficient heat thereto (and cooling with air, if necessary), and the substrate material may produce an aerosol that is “smoke-like.” In other aspects, the substrate material may produce an aerosol that is substantially non-visible but is recognized as present by other characteristics, such as flavor or texture. Thus, the nature of the produced aerosol may be variable depending upon the specific components of the aerosol delivery component. The substrate material may be chemically simple relative to the chemical nature of the smoke produced by burning tobacco.

In some implementations, the aerosol precursor composition may incorporate nicotine, which may be present in various concentrations. The source of nicotine may vary, and the nicotine incorporated in the aerosol precursor composition may derive from a single source or a combination of two or more sources. For example, in some implementations the aerosol precursor composition may include nicotine derived from tobacco. In other implementations, the aerosol precursor composition may include nicotine derived from other organic plant sources, such as, for example, non-tobacco plant sources including plants in the Solanaceae family. In other implementations, the aerosol precursor composition may include synthetic nicotine. In some implementations, nicotine incorporated in the aerosol precursor composition may be derived from non-tobacco plant sources, such as other members of the Solanaceae family. The aerosol precursor composition may additionally, or alternatively, include other active ingredients including, but not limited to, botanical ingredients (e.g., lavender, peppermint, chamomile, basil, rosemary, thyme, eucalyptus, ginger, cannabis, ginseng, maca, and tisanes), stimulants (e.g., caffeine and guarana), amino acids (e.g., taurine, theanine, phenylalanine, tyrosine, and tryptophan) and/or pharmaceutical, nutraceutical, and medicinal ingredients (e.g., vitamins, such as B6, B12, and C and cannabinoids, such as tetrahydrocannabinol (THC) and cannabidiol (CBD)). It should be noted that the aerosol precursor composition may comprise any constituents, derivatives, or combinations of any of the above.

As noted herein, the aerosol precursor composition may comprise or be derived from one or more botanicals or constituents, derivatives, or extracts thereof. As used herein, the term “botanical” includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, Ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

A wide variety of types of flavoring agents, or materials that alter the sensory or organoleptic character or nature of the mainstream aerosol of the smoking article may be suitable to be employed. In some implementations, such flavoring agents may be provided from sources other than tobacco and may be natural or artificial in nature. For example, some flavoring agents may be applied to, or incorporated within, the substrate material and/or those regions of the smoking article where an aerosol is generated. In some implementations, such agents may be supplied directly to a heating cavity or region proximate to the heat source or are provided with the substrate material. Example flavoring agents may include, for example, vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach and citrus flavors, including lime and lemon), maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, and flavorings and flavor packages of the type and character traditionally used for the flavoring of cigarette, cigar, and pipe tobaccos. Syrups, such as high fructose corn syrup, may also be suitable to be employed.

As used herein, the terms “flavor,” “flavorant,” “flavoring agents,” etc. refer to materials which, where local regulations permit, may be used to create a desired taste, aroma, or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavor materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, Ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

In some implementations, the flavor comprises menthol, spearmint and/or peppermint. In some embodiments, the flavor comprises flavor components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.

In some implementations, the flavor may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

Flavoring agents may also include acidic or basic characteristics (e.g., organic acids, such as levulinic acid, succinic acid, pyruvic acid, and benzoic acid). In some implementations, flavoring agents may be combinable with the elements of the substrate material if desired. Example plant-derived compositions that may be suitable are disclosed in U.S. Pat. No. 9,107,453 and U.S. Pat. App. Pub. No. 2012/0152265 both to Dube et al., the disclosures of which are incorporated herein by reference in their entireties. Any of the materials, such as flavorings, casings, and the like that may be useful in combination with a tobacco material to affect sensory properties thereof, including organoleptic properties, such as described herein, may be combined with the substrate material. Organic acids particularly may be able to be incorporated into the substrate material to affect the flavor, sensation, or organoleptic properties of medicaments, such as nicotine, that may be able to be combined with the substrate material. For example, organic acids, such as levulinic acid, lactic acid, pyruvic acid, and benzoic acid may be included in the substrate material with nicotine in amounts up to being equimolar (based on total organic acid content) with the nicotine. Any combination of organic acids may be suitable. For example, in some implementations, the substrate material may include approximately 0.1 to about 0.5 moles of levulinic acid per one mole of nicotine, approximately 0.1 to about 0.5 moles of pyruvic acid per one mole of nicotine, approximately 0.1 to about 0.5 moles of lactic acid per one mole of nicotine, or combinations thereof, up to a concentration wherein the total amount of organic acid present is equimolar to the total amount of nicotine present in the substrate material. Various additional examples of organic acids employed to produce a substrate material are described in U.S. Pat. App. Pub. No. 2015/0344456 to Dull et al., which is incorporated herein by reference in its entirety.

The selection of such further components may be variable based upon factors such as the sensory characteristics that are desired for the smoking article, and the present disclosure is intended to encompass any such further components that are readily apparent to those skilled in the art of tobacco and tobacco-related or tobacco-derived products. See, Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp. (1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products (1972), the disclosures of which are incorporated herein by reference in their entireties.

In other implementations, the substrate material may include other materials having a variety of inherent characteristics or properties. For example, the substrate material may include a plasticized material or regenerated cellulose in the form of rayon. As another example, viscose (commercially available as VISIL®), which is a regenerated cellulose product incorporating silica, may be suitable. Some carbon fibers may include at least 95 percent carbon or more. Similarly, natural cellulose fibers such as cotton may be suitable, and may be infused or otherwise treated with silica, carbon, or metallic particles to enhance flame-retardant properties and minimize off-gassing, particularly of any undesirable off-gassing components that would have a negative impact on flavor (and especially minimizing the likelihood of any toxic off-gassing products). Cotton may be treatable with, for example, boric acid or various organophosphate compounds to provide desirable flame-retardant properties by dipping, spraying or other techniques known in the art. These fibers may also be treatable (coated, infused, or both by, e.g., dipping, spraying, or vapor-deposition) with organic or metallic nanoparticles to confer the desired property of flame-retardancy without undesirable off-gassing or melting-type behavior.

More specific formats, configurations and arrangements of components within the non-combustible aerosol provision systems of the present disclosure will be evident in light of the further disclosure provided hereinafter. Additionally, the selection and arrangement of various non-combustible aerosol provision system components can be appreciated upon consideration of the commercially available electronic non-combustible aerosol provision systems, such as those representative products referenced in the background art section of the present disclosure.

According to certain aspects of the present disclosure, it may be advantageous to provide an aerosol delivery device that is easy to use and that provides reusable and/or replaceable components. FIGS. 1A, 1B, and 2 illustrate one example implementation of such a device. In particular, FIGS. 1A and 1B illustrate a perspective view and a cross-sectional perspective view, respectively, of an aerosol delivery device 100 that includes a removable cartridge 106, an actuator assembly 108, and a bottom access door 188 for loading and removing the cartridge 106. FIG. 2 provides an exploded view of the aerosol delivery device 100. The aerosol delivery device 100 includes a holder 102 comprising a main body defining a proximal end 102a and a distal end 102b, the main body further defining a receiving chamber 110 configured to receive the removable cartridge 106 therein and a first aerosol passageway 150 that extends through at least a portion of the main body. The cartridge 106 includes an ignitable heat source 120 and a substrate portion 122 comprising an aerosol precursor composition configured to form an aerosol upon application of heat thereto.

The device 100 further includes a mouthpiece 104 having a first end and a longitudinally opposed second end with a second aerosol passageway 154 extending longitudinally therebetween. The first end is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the holder 102. The mouthpiece 104 is configured to sealingly engage with the proximal end 102a of the holder so that the first and second aerosol passageways 150, 154 are in fluid communication so as to deliver the aerosol generated in the receiving chamber to the user. The mouthpiece 104 may be removably coupled to the holder 102 to, for example, provide for cleaning or customization of the device 100. However, in other implementations, the mouthpiece 104 may be integrally formed with the holder 102.

The device 100 further includes the access door 188 movably coupled to the distal end 102b of the main body that defines a third aerosol passageway 147. In an open configuration, the access door 188 provides access to the receiving chamber 110 for loading the removable cartridge 106 therein and, in a closed configuration, fluidly couples the receiving chamber 110 with the first aerosol passageway 150 via the third aerosol passageway 147. The device 100 includes a slide mechanism 185 or similar structure to move the door 188 into the open configuration. In some implementations, the door 188 is coupled to the holder 102 via a detent hinge configured maintain the access door 188 in at least one of the open configuration or the closed configuration.

FIG. 1C depicts an alternative implementation where the third aerosol passageway 147′ is defined in the distal end 102b′ of the main body and fluidly couples the receiving chamber 110′ with the first aerosol passageway 150′. The access door 188′ may be solid or include a recess 147a′ that partially forms the third aerosol passageway as shown in FIG. 1C. In some implementations, the third aerosol passageway 147′, 147a′ is configured to redirect the vapor path 143′ by approximately 180°.

The main body defines an opening 182 therethrough that is in fluid communication with the receiving chamber 110 and oriented so as substantially align with the ignitable heat source 120 when the removable cartridge 106 is loaded within the receiving chamber. As shown in the depicted implementation, the opening 182 is disposed within a side wall of the main body 102 and may be configured to allow for air intake therethrough and/or viewing of the ignitable heat source. The holder 102 also houses a power source 112, a printed circuit board 118 with associated electronics, including a controller, and a pair of ignitor contacts 128 in electrical communication with the power source 112, disposed proximate the opening 182 and configured to engage the ignitable heat source when the removable cartridge is loaded within the receiving chamber. The device 100 further includes an ignition switch 140 in electrical communication with the power source 112 and the ignitor contacts 128 and configured to provide power to the contacts when actuated. In some implementations, the printed circuit board 118 may include a charging port 119 disposed thereon and oriented so that the charging port is disposed at the distal end of the holder 102 (e.g., under the access door 188 as shown in FIG. 4B). In the depicted implementation, the opening 182 includes a guard 111 configured to prevent a user from inadvertently contacting the ignitor contacts 128 and/or the ignitable heat source 120. In some implementations, the holder 102 further defines an enlarged cavity 138 that in some implementations is a portion of the receiving chamber 110 and is configured to provide an area about the ignitable heat source 120 for ignition components, such as the contacts 128, and/or for providing spacing between the heat source 120 and the holder 102 to minimize or eliminate heat transfer therebetween. The ignitor contacts 128 are static and configured to deflect slightly when contacted by the cartridge 106 so as to allow the ignitable heat source 120 to be disposed between and in contact with the ignitor contacts 128.

The actuator assembly 108 is slidably disposed within the holder 102 and is configured to contact the removable cartridge 106 when loaded within the receiving chamber and eject the cartridge out of the distal end 102b of the holder. As further illustrated in FIGS. 2, 7A, and 7B, the actuator assembly 108 comprises a generally elongate slider body 130 disposable within the main body so as to slide along a length thereof in a first direction and a second direction. The slider body 130 includes a first protrusion 131 (e.g., a slider button) extending from an outer surface thereof and extending through an opening 116 in a wall of the holder 102 that is configured to move the slider body 130 between a loading position (see FIG. 3A) and an ejecting position (see FIGS. 3C and 7A). The slider body 130 further includes a second protrusion or stem 133 extending from a distal end thereof. The stem 133 is configured to engage the removable cartridge 106 so as to advance the removable cartridge through the distal end of the holder 102 when the actuator assembly 108 is moved into the ejecting position. The actuator assembly 108 is disposed within a cavity within the holder and outside of any aerosol passageway.

The operation of the device 100 generally, and the actuator assembly 108 specifically, is described with respect to FIGS. 3A-3C, which illustrate a series of views of the aerosol delivery device 100 in various states of operation. Specifically, FIG. 3A represents the cartridge 106 being loaded into the device 100 (i.e., the actuator assembly 108 in the loading position), FIG. 3B represents the device 100 during ignition and use, and FIG. 3C represents the cartridge 106 being ejected from the device 100 (i.e., the actuator assembly in the ejection position).

Referring to FIGS. 3A and 4A-4E, in order to load the cartridge into the receiving chamber 110, the slide mechanism 185 is moved towards the distal end 102b of the holder so as to deflect or otherwise move the access door 188 into the open configuration (see FIG. 4B), exposing the receiving chamber 110 via opening 115 and the first and third aerosol passageways 150, 147 (see FIG. 4E). The cross-sectional area of the first aerosol passageway 150 is preferably less than the cross-sectional area of the opening 115 to prevent the cartridge from being inserted into the aerosol passageway 150. The actuator assembly 108 is fully retracted towards the mouthpiece 104. The cartridge 106 is manually inserted in the receiving chamber 110 of the holder 102, so as to locate the cartridge 106 into a lighting and/or use positon, where the cartridge is sealingly secured within the chamber 110 via the retention mechanism 176 (see FIGS. 1B and 3B) so that the ignitable heat source 120 operatively aligns with the ignitor contacts 128 (see FIG. 4C). After loading, the access door 188 is moved into the closed configuration (see FIG. 4D) so as to sealingly engage the access door 188 with the distal end of the holder 102 via a gasket 117 or other sealing mechanism so that there is no aerosol leakage or air ingress therebetween. The receiving chamber 110, third aerosol passageway 147 and the first aerosol passageway 150 are in fluid communication. In the closed configuration, the cartridge 106 is secured within the holder so as to be in fluid communication with the aerosol passageways. The ignitable heat source 120 is in contact with the ignitor contacts 128 and may be ignited so that the cartridge may be consumed (i.e., aerosol generated and delivered to the user via the aerosol passageways). After which, the cartridge 106 may be ejected from the device 100 as described below.

With reference to FIGS. 3B, 5A, and 5B, in the lighting/use position, the cartridge 106 is disposed within the receiving chamber 110, with the ignitable heat source 120 disposed within the cavity 138 and in contact with the ignitor contacts 128. The opening 182, as shown in FIG. 5B, includes two separate openings 182a, 182b with a portion of the holder sidewall forming the guard 111. In the depicted implementation, the ignitor push button 140, when pressed by a user, activates the ignitor contacts 128 thereby igniting the heat source 120 of the cartridge 106. Specifically, once the push button 140 is actuated, the electrical circuit is completed and electricity is delivered to the ignitor contacts 128. In some implementations, the ignitor contacts 128 will only remain activated while the ignitor push button 140 is depressed. As such, in some implementations, the ignitor contacts 128 will be deactivated when the ignitor push button 140 is released. In some implementations, the ignitor push button 140 may be configured to activate the ignitor contacts 128 for a set time after release. In one implementation, the push button 140 is disposed on the side of the aerosol delivery device 100. The button 140 is movably coupled to the holder, with or without a sealing arrangement. The button 140 may be spring loaded so as to return to an off position after igniting the heat source 120. The device 100 may include a LED that may illuminate during ignition and/or change colors to indicate a state of the device 100. Additionally, a user may be able to observe ignition via the opening 182.

FIG. 6 depicts the vapor path 143 that runs through the device 100 when in use, for example, when a user draws on the holder 102 (e.g., via the mouthpiece 104), ambient air may be drawn into the cavity 138 via the opening 182, travel through the cartridge 106 where the air mixes with the aerosol produced by the cartridge, and then travel through the various aerosol passageways for inhalation by the user. Specifically, the aerosol mixture exiting the cartridge 106 enters the third aerosol passageway 147, which is configured to redirect the mixture (i.e., vapor path) about 180° into the first aerosol passageway 150, which extends substantially the entire length of the main body. The first aerosol passageway 150 is in fluid communication with the second aerosol passageway 154 within the mouthpiece 104, so that the vapor is delivered to the user via opening 158 in the mouthpiece portion 104. One benefit of the long vapor path 143 is that it may be configured to reduce or otherwise optimize the vapor temperature leaving the device 100.

Ejection of the cartridge 106 is described with reference to FIGS. 3C, 7A, and 7B. Generally, the ejection mechanism (i.e., actuator assembly 108) is configured to eject the cartridge 106 from the distal end 102b of the holder via opening 115 when the access door 188 is in the open configuration. Prior to ejection, one end of the cartridge 106 engages the retention mechanism 176, which is configured to retain the cartridge in the receiving chamber. In some implementations, the mechanism 176 is a silicone seal configured to frictionally and/or sealingly engage the cartridge so that when the cartridge 106 is pushed into and fully received within the receiving chamber 110, the cartridge 106 is temporarily “locked” in place.

As shown in FIG. 7B, the actuator assembly 108 is moved forward (i.e., away from the mouthpiece) by a user using, for example, their thumb and the protrusion 131 to move the actuator assembly 108 in the first and second directions as needed. The slider protrusion 131 (and actuator assembly 108) is moved forward until the inner stem 133 of the slider body 130 engages the cartridge 106 pushing it forward and disengaging the cartridge from the retention mechanism 176 (see FIG. 7A). As can be seen in FIG. 7B, the inner stem 133 enters the cavity 138 prior to engaging the ignitable heat source 120 of the cartridge. Once engaged, the cartridge 106 is pushed out of the receiving chamber 110 and out of the aerosol delivery device 100. After which, the cartridge 106 may be pulled out of or allowed to drop out of the device 100.

After ejection, a user may insert a new cartridge or simply close the access door 188 and store the device 100 for later use. In some implementations, the device 100 may include a latching mechanism (not shown) configured to further secure the access door 188 in the closed configuration. In some implementations, the latching mechanism may include a magnetic engagement, a snap-fit, a detent, and/or be spring-loaded into the closed configuration.

In some alternative implementations, the aerosol is generated by an electric heater configured to perform electric heating in which electrical energy from the power source is delivered to the heater when the actuator assembly is moved into the lighting/use position. Subjecting the aerosol-generating material (e.g., substrate 122) to heat releases one or more volatiles from the aerosol-generating material to form an aerosol. Examples of suitable forms of electric heating include resistance (Joule) heating, induction heating, dielectric and microwave heating, radiant heating, arc heating and the like. More particular examples of suitable electric heaters include resistive heating elements such as wire coils, flat plates, prongs, conductive meshes, radiant heaters, conductive inks, micro heaters or the like.

In some examples, the cartridge 106 may include a susceptor (e.g., the susceptor may be part of the substrate 122). The susceptor is a material that is heatable by penetration with a varying magnetic field generated by a magnetic field generator that may be separate from or part of the aerosol generator. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor in some examples may be both electrically-conductive and magnetic, so that the susceptor of these examples is heatable by both heating mechanisms.

FIGS. 8A, 8B, and 9 illustrate another example implementation of an aerosol delivery device 200. In particular, FIGS. 8A and 8B illustrate a perspective view and a cross-sectional perspective view, respectively, of an aerosol delivery device 200 that includes a removable cartridge 206, a slider assembly 208, and a separate ignition actuator 240. The aerosol delivery device 200 includes a two-part holder comprising an upper body portion 201 and a lower body portion 203, each defining a proximal end and a distal end. However, in alternative implementations, the holder 202 may comprise a single body with alternative loading mechanisms.

The lower body portion 203 defines a receiving chamber 210 disposed therein and configured to receive a removable cartridge 206 comprising an ignitable heat source 220 and a substrate portion that includes a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat thereto. The lower body portion 203 includes a pair of actuatable ignitor contacts 228 disposed proximate the distal end thereof and coupled thereto via a pair of elongate bodies or arms 226. The actuatable ignitor contacts 228 are configured to be engageable with the ignitable heat source 220 when the removable cartridge 206 is secured within the receiving chamber 210. Specifically, the ignitor contacts 228 are configured to be movable between a first position spaced apart from the ignitable heat source 220 and a second position contacting the ignitable heat source 220.

In the depicted implementation, each contact 228 and elongate body 226 are formed from a single flat strip of metal (e.g., copper, silver, gold, or other conductive material) where one end is curled or otherwise shaped to form the ignitor contact 228, while the other end remains substantially flat to form the contact arm 226. Alternatively, the contacts 228 and elongate bodies 226 may be formed from a single strip of material, where each end is curled or otherwise shaped to form the first and second ignitor contacts 228 and the middle portion is bent or otherwise shaped to at least partially surround the receiving chamber 210. The middle portion forms a single elongate body 226 that extends on each side of the receiving chamber 210, such that the ignitor contacts 228 may be deflected towards one another and into contact with the ignitable heat source 220. The bend in the single elongate body 226 provides a spring force to bias the ignitor contacts into their first position.

Additionally, the lower body portion 203 includes a window 282 disposed therein and configured to provide a view of at least a portion of the receiving chamber 210 so that a user may observe the cartridge 208 and/or electrical contacts 228. All or a portion of the window may comprise a transparent or translucent material (e.g., a glass material, a polycarbonate, polyethylene terephthalate, acrylic, or the like). In some implementations, a portion of the lower body portion 203 may be made from a transparent or translucent material.

The upper body portion 201 houses a power source 212, a printed circuit board 218 with associated electronics, and the sliding actuator assembly 208. The sliding actuator assembly 208 is slidably disposed within the upper body portion 201 and is configured to eject the removable cartridge from the lower body portion 203. The upper body portion 201 further defines a first aerosol passageway 250. The upper body portion 201 and the lower body portion 203 are movably coupled together via a mechanism 284 (e.g., a swivel joint), so as to enable the lower body portion 203 to rotate relative to the upper body portion 201 to expose the receiving chamber 210 and provide access to load the removable cartridge therein. In some implementations, the aerosol delivery device 200 further comprises a locking mechanism 285 disposed on at least one of the lower body portion 203 or the upper body portion 201 that is configured to maintain the device in a closed orientation (e.g., the upper and lower body portions aligned and in fluid and/or electrical communication). The locking mechanism 285 may include, for example, one or more of magnets, friction, a snap fit, or a detent. However, in some other implementations, the upper body portion 201 and the lower body portion 203 are integrally formed together, or may be fixedly coupled with one another. Other manners of movably coupling the upper body portion 201 and the lower body portion 203 include a hinge joint, a sliding track, and the like.

The device 200 further comprises a mouthpiece 204 having a first end 204a and a longitudinally opposed second end 204b with a second aerosol passageway 254 extending longitudinally therebetween. In the depicted implementation, the mouthpiece 204 is located at the proximal end of the upper body portion 201, with the first end configured to engage with a user's mouth and the second end configured to engage the proximal end of the upper body portion 203. The mouthpiece 204 is configured to sealingly engage with the upper body portion 201 so that the first and second aerosol passageways 250, 254 are in fluid communication so as to deliver the aerosol generated in the receiving chamber to the user. The mouthpiece 204 may be removably coupled to the upper body portion 201 to, for example, provide for cleaning or customization of the device 200. However, in other implementations, the mouthpiece 204 may be integrally formed with the upper body portion 201.

As further illustrated by the exploded view of FIG. 9, the slider actuator assembly 208 comprises a generally tubular slider body 230 disposable within the upper body portion 201 so as to slide along a length of the upper body portion 201 in a first direction and a second direction. The slider body 230 defines a recess 238 (see e.g., FIG. 11A) extending therethrough that forms a portion of the first aerosol passageway 250 through the upper body portion 201. The slider body 230 includes a first protrusion 231 extending from an outer surface thereof and extending through an opening 216 in a wall of the upper body portion 201 that is configured to move the slider body 230 between a loading position (see FIGS. 10A-10E) and an ejecting position (see FIGS. 12A and 12B). The slider body 230 further includes a second protrusion or stem 233 extending from a distal end thereof. The stem 233 is configured to engage the removable cartridge 206 so as to advance the removable cartridge through the distal end of the lower body portion 203 when the actuator assembly 208 is moved into the ejecting position. Portions of the protrusions 231, 233 extend into the receptacle 238 such that the vapor/air path splits around those portions. Specifically, one or more portions of the first protrusion, the second protrusion, or both may extend into the portion of the second aerosol passageway defined by the receptacle 238 within the slider body 230 so that the aerosol generated by the cartridge 206 and pulled into the mouthpiece 204 is split by the one or more portions when traveling through the tubular body. In some implementations, the slider body 230 comprises a longitudinally oriented baffle 239 extending inwardly from an interior wall thereof, where the baffle divides the aerosol passageway 250 extending through slider body.

The upper body portion 201 further defines two cavities 207, 209, where the first cavity 207 is configured to receive the slider body 230 and the second cavity is configured to house the power source 212 and the printed circuit board 218. Additionally, the actuator assembly 208, specifically the slider body 230, includes a sealing arrangement for sealingly engaging with an internal surface of the first cavity 207 (e.g., to avoid aerosol leakage or undesirable air ingress). In the depicted implementation, the sealing arrangement comprises a pair of O-rings 260 disposed within grooves 261 disposed proximate the distal and proximal ends of the slider body 230. However, other configurations of the sealing arrangement are contemplated and considered within the scope of the disclosure.

The lower body portion 203 also defines two cavities 207′ (includes receiving chamber 210), 209′ that (in a closed configuration) are generally aligned with the cavities 207, 209 of the upper body portion 201. Specifically, the first cavity 207′ is defined by the receiving chamber 210 and opposing openings 215, 215′ and in some implementations includes a bar 211 or other structure for supporting the window 282 and/or guiding the cartridge 206 during insertion. In the depicted implementation, the lower body portion 203 defines a cut-out or other opening that exposes the receiving chamber 210 and is configured to receive the window 282 therein. The window 282 may be installed or otherwise coupled to the lower body portion 203 via an adhesive, snap fit, or other means known in the art. The cavity 207′/receiving chamber 210 includes a groove or other structure for securing a retention mechanism 276 therein that frictionally and/or sealingly engages with an outer surface of the cartridge 206 as described below. In the depicted implementation, the retention mechanism 276 is an O-ring.

The second cavity 209′ is generally configured to house various electronics and other mechanisms necessary to provide power to the ignitor contacts 228 and actuate same for igniting the heat source 220 of the cartridge 206. For example, the contact arms 226 are electrically coupled to the power source within the second cavity 209′ and extend through a wall of the second cavity 209′ so as position the ignitor contacts 228 within the receiving chamber 210. The lower body portion 203 further defines a set of openings 263 therethrough that are configured to engage with the actuator buttons 240 and light emitting diodes (LED) 241 that are disposed on both sides of the lower body portion 203 and are described below.

The operation of the device 200 generally, and the slider actuator assembly 208 specifically, is further described with respect to FIGS. 10A-12B, which illustrate a series of views of the aerosol delivery device 200 in various states of operation. Specifically, FIGS. 10A-10E represent the cartridge 206 being loaded into the device 200 (i.e., the actuator assembly in the loading position), FIGS. 11A-11C represent the device 200 during ignition, and FIGS. 12A and 12B represent the cartridge 206 being ejected from the device 200 (i.e., the actuator assembly in the ejection position).

Referring to FIGS. 10A and 10B, in order to load the cartridge into the receiving chamber 210, the lower body portion 203 is rotated or otherwise offset (e.g., twisted) from the upper body portion 201 so as to expose the receiving chamber 210 via opening 215′. Prior to rotating the body portions, the actuator assembly 208 is moved into the loading position (i.e., fully retracted towards the mouthpiece 204) so that the sliding body 230 is fully disposed within the first cavity 207 of the upper body portion 201. The cartridge 206 is manually inserted in the receiving chamber 210 of the lower body portion 203 (see FIG. 10C), so as to locate the cartridge 206 into a lighting and/or use positon, where the cartridge is sealingly secured within the chamber 210 via the retention mechanism 276 so that the ignitable heat source 220 operatively aligns with the ignitor contacts 228 (see FIG. 10D). After loading, the upper and lower body portions are moved back into alignment so that the sealed end of the cartridge 206 is in fluid communication with the first aerosol passageway 250 (see FIGS. 10E and 11A). The fit between the upper and lower body portions is such that there is no aerosol leakage or air ingress therebetween, with or without the use of additional sealing arrangements.

With reference to FIGS. 11A-11C, in the lighting/use position, the distal end of the cartridge 206 is located proximate the distal end of the lower body portion 203 such that the cartridge 206 is located inside of the receiving chamber 210. In particular, in the lighting/use position of the depicted implementation, the heat source 220 portion of the cartridge 206 is also positioned proximate the distal end of the lower body portion 203 and aligned with the ignitor contacts 228 in the lighting position (see FIG. 11A). The heat source 220 is ignited via the aligned push buttons 240 disposed on the opposite sides of the lower body portion 203 of the aerosol delivery device 200. The buttons 240 are movably coupled to the lower body portion, with or without a sealing arrangement, so that a user may depress both buttons simultaneously (e.g., via a pinching action) so as to engage and deflect the contact arms 226 and by extension move the ignitor contacts 228 into contact with the ignitable heat source 220. Once released, the buttons 240 return to their original position, at least in part via a spring action from the deflected contact arms 226 and/or a return biasing element. The device 200 includes a pair of LEDs 241 that may illuminate during ignition and/or change colors to indicate a state of the device 200. Additionally, a user may be able to observe ignition via the window 282.

FIGS. 11B and 11C depict distal end views of the aerosol delivery device 200 that further illustrate actuation of the ignitor contacts 228. Specifically, FIG. 11B depicts the ignitor contacts 228 in a first, unactuated position where the ignitor contacts 228 are positioned near, but not in contact with, the ignitable heat source 220. As can be seen through the opening 215 in the distal end of the lower body portion 203 (generally, the holder), there are two openings 221 (only one is shown) provided between the cavities 207′, 209′ (see FIG. 9) through which the elongate bodies 226 extend. Two spring loaded buttons 240 are disposed on opposing sides of the holder 203 and each extends slightly above an outer surface of the holder. The buttons 240 are oriented proximate the elongate bodies 226 and configured to contact the elongate bodies 226 when pressed. Also depicted is a charging port 219.

FIG. 11C depicts the ignitor contacts 228 in a second, actuated position where the contacts 228 are in contact with the ignitable heat source 220. As shown, the spring loaded push buttons 240 are simultaneously pressed to activate ignition. Specifically, when the buttons 240 are pressed, power is activated and the ignitor contacts 228 are pushed into contact with the ignitable heat source 220. Releasing the buttons 240 terminates power and the ignitor contacts pull away from tip automatically (e.g., return to their first position). In various implementations, the device 200 may be programmed so that the ignitor contacts are de-energized after the push button 240 is released and/or after a set period of time (e.g., 30 seconds). Similarly, the contacts 228 may be energized as long as the button 240 is depressed or for a set period of time, for example, a time sufficient for ignition to be achieved. The LEDs 241 on both sides illuminate when the buttons 240 are pressed, although in other implementations, the LEDs may illuminate and/or change colors to indicate a status of the device. In addition, a user can see the tip (ignitable heat source 220) of the cartridge 206 ignite through the optional window 282.

In some implementations, the device 200 may include an ejection mechanism as shown in FIGS. 12A and 12B. Generally, the ejection mechanism is configured to eject the cartridge 206 from the distal end of lower body portion 203 via opening 215; as opposed to the proximal end through which the cartridge is loaded. Between loading and ejection, the cartridge 206 passes through the first cavity 207′. In one implementation, the ejection mechanism is incorporated in to the actuator assembly 208 so that when the slider protrusion 231 (and actuator assembly 208) is moved forward, the stem 233 engages one end of the cartridge 206 and pushes the cartridge out of the receiving chamber 210 and out of the aerosol delivery device 200 through the opening 215 in the lower body portion 203. Specifically, a user can slide the actuator assembly 208 forward (i.e., away from the mouthpiece) using, for example, their thumb and the protrusion 231 so that the inner stem 233 of the slider body 230 engages the cartridge 206 pushing it forward and disengaging the cartridge from the retention mechanism 276. After which, the cartridge 206 may be pulled out or allowed to drop out of the device 200.

FIG. 12A depicts the device 200 prior to ejection, where the actuator assembly 206 is fully retracted and the slider body 230 fully disposed within the cavity 209. As shown, the proximal end of the cartridge 206 engages the retention mechanism 276, which is configured to retain the cartridge in the receiving chamber. In some implementations, the mechanism 276 is a silicone seal configured to frictionally and/or sealingly engage the cartridge so that when the cartridge 206 is pushed into and fully received within the receiving chamber 210, the cartridge 206 is temporarily “locked” in place.

As shown in FIG. 12B, the actuator assembly 208 is moved forward into the ejecting position (i.e., away from the mouthpiece) so that a portion of the stem 233 enters into the cavity 207′ of the lower body portion 203 and engages the cartridge 206. As the actuator assembly is moved forward, the stem 233 pushes the cartridge forward so that the cartridge 206 becomes disengaged from the cartridge retention mechanism 276.

FIGS. 13A-13C, 14, and 15 illustrate another example implementation of an aerosol delivery device 300. In particular, FIGS. 13A-13C illustrate perspective views and a cross-sectional side view of an aerosol delivery device 300 that includes a translating mouthpiece 304 and a removable cartridge 306. Specifically, the aerosol delivery device 300 includes a holder 302 comprising a main body defining a proximal end 302a and a distal end 302b, the main body further defining a receiving chamber 310 configured to receive the removable cartridge 306 comprising an ignitable heat source therein and a receptacle 338 that extends along at least a portion of the main body. The mouthpiece 304 is movably coupled to the main body and includes a first end and a longitudinally opposed second end with a first aerosol passageway 350 extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the holder. The mouthpiece 304 is configured to translate between an open configuration where the receiving chamber 310 is exposed for loading of the removable cartridge 306 (see FIG. 13C) and a closed configuration (see FIGS. 13A and 14) where the first aerosol passageway 350 is generally aligned with the receiving chamber 310 (e.g., in fluid communication therewith).

The aerosol delivery device 300 further includes a translating mechanism 387 movably coupled to the main body and at least partially disposed within the receptacle 338. The translating mechanism 387 is configured to couple the mouthpiece 304 to the holder 302 and bias the mouthpiece into the closed configuration. As further shown in FIGS. 14 and 15, the device 300 may include a retention mechanism 369 that couples the translating mechanism 387 to the holder 302 and retains a portion of the translating mechanism 387 within the recess. In the depicted implementation, the receptacle 338 is defined by an open slot or similar structure where the main body is “removed” so as to expose a cavity (i.e., receptacle 338). The receptacle 338, or a portion of a perimeter thereof, includes a first portion of the retention structure 369a disposed thereon or therein and configured to engage with a mating portion of the retention structure 369b disposed on the translating mechanism 387. The retention structure 369 may be a snap-fit mechanism or other type of reversible coupling mechanism that movable couples the mechanism 387 to the holder 302. In some implementation, the retention structure 369 may permanently, but movably, affix the mechanism 387 to the holder.

The translating mechanism 387 comprises a body portion 387a that defines a passageway 383 therethrough that is configured to slidably receive at least a portion of the mouthpiece 304 and a tab 387b that extends from a proximal end thereof and is configured to engage the holder 302 and at least partially enclose the receptacle 338. As can be seen in FIG. 14, the mouthpiece 304 includes a first enlarged portion 307 disposed at the first end of the mouthpiece 304 and a second elongate portion 305 extending from the enlarged portion 307 to the second end of the mouthpiece 304. The elongate portion 305 of the mouthpiece slides freely within the passageway 383 and may slide in a first direction to orient the elongate portion at least partially within the receiving chamber 310 to eject the removable cartridge from the distal end of the main body and in a second direction, to orient the elongate portion within the passageway 383 and possibly remove the mouthpiece from the translating mechanism 387, as described in greater detail below. The translating mechanism 387 further defines a cavity 389 disposed in the proximate end thereof that is configured to receive the mouthpiece 304. The cavity 389 is coextensive with and has a larger cross-sectional shape than the passageway 383, and is configured to engage the enlarged portion 307 of the mouthpiece to limit travel of the mouthpiece in the second direction. Specifically, the elongate portion 305 may be inserted into the translating mechanism 387 via the cavity 389 and passageway 383, where the distal end of the cavity 389 forms a stop preventing the enlarged portion 307 from entering the passageway 383 and the mouthpiece 304 from exiting the distal end 302b of the main body.

The translating mechanism 387, the holder 302, or both include one or more biasing elements 339, 342 to position the translating mechanism 387 and/or the mouthpiece 304 relative to the holder 302, and the translating mechanism 387 and/or the mouthpiece 304 may include a sealing mechanism 360 configured to seal the first aerosol passageway 350 with the receiving chamber 310 as described below. For example, the mouthpiece 304 may be translated into the receptacle 338 upon application of a force to the translating mechanism 387 (e.g., a user pressing on the translating mechanism with their thumb), where a spring or similar biasing mechanism 339 disposed between the receptacle 338 and the translating mechanism 387 is configured to apply an outward force on the translating mechanism.

In addition, the holder 302 houses a power source 312 and a printed circuit board 318, along with associated electrical components. Similar to device 100, a pair of actuatable ignitor contacts 328 are disposed proximate the distal end thereof and coupled thereto via a pair of elongate bodies or arms 326. The actuatable ignitor contacts 328 are configured to be engageable with the ignitable heat source 320 when the removable cartridge 306 is secured within the receiving chamber 310. The holder 302 further includes various electronics and other mechanisms necessary to provide power to the ignitor contacts 328 and actuate same for igniting the heat source 320 of the cartridge 306. The pair of contact arms 326 are electrically coupled to the power source 312 with two spring loaded push buttons 340 disposed on opposing sides of the holder 302 and configured to contact the elongate bodies 126 when pressed, so as to move the ignitor contacts 328 into contact with the ignitable heat source 320. The distal end of the holder 302 further defines a set of openings 363 therethrough that are configured to engage with the actuator buttons 340 and light emitting diodes (LED) 341 that are disposed on both sides of the holder 302. Also depicted is a charging port 319.

The operation of the device 300 generally, and the translation of the mouthpiece 304 specifically, is further described with respect to FIGS. 16 and 17, which illustrate a series of views of the aerosol delivery device 300 in various states of operation. Specifically, FIGS. 16A-16D represent the cartridge 306 being loaded into the device 300 (i.e., the mouthpiece in an open configuration) and FIGS. 17A and 17B represent the mouthpiece 304 being actuated to eject the cartridge 306 from the device 300, where the translating mechanism 387 and the mouthpiece are in the closed configuration. The operation of the device 300 with respect to ignition is described herein below with respect to FIGS. 18A-18C.

Referring to FIG. 16A, in order to load the cartridge into the receiving chamber 310, a transverse force (A) is applied to the translating mechanism 387 that is sufficient to overcome the resistance of the biasing element 339 so that the translating mechanism 387 and a portion of the mouthpiece 304 are recessed into a cavity of the receptacle 338 as shown in FIGS. 16B and 16C. With the device 300 in the open configuration (i.e., mouthpiece translated into the receptacle), the receiving chamber 310 is exposed and the cartridge 306 may be manually inserted in the receiving chamber 310, heating section 320 first (see FIG. 16B). In some implementations, the receiving chamber 310 includes a bar 311 or other structure for supporting and/or guiding the cartridge 306 during insertion (see FIG. 14).

As shown in FIG. 16C, the cartridge 306 is fully inserted into the chamber 310 so as to locate the cartridge 306 into a lighting and/or use positon, where the cartridge is sealingly secured within the chamber 310 via the retention mechanism 376 so that the ignitable heat source 320 operatively aligns with the ignitor contacts 328, all while maintaining the translating mechanism 387 in the open configuration, either manually or via a type of locking or retention mechanism (not shown). After loading, the mouthpiece 304 and translating mechanism 387 are moved back into the closed configuration so that the sealed end of the cartridge 306 is in fluid communication with the first aerosol passageway 350 (see FIGS. 14 and 16D). The fit between the translating mechanism and the holder 302 is such that there is little to no aerosol leakage or air ingress therebetween, with or without the use of additional sealing arrangements. For example, as shown in FIG. 14, an O-ring or similar sealing mechanism 360 may be disposed at the distal end of the mouthpiece 304 or translating mechanism 387 so as to further seal the first aerosol passageway 350 with the receiving chamber 310.

In some implementations, the translating mouthpiece 304 of the device 300 is also configured as an ejection mechanism as shown in FIGS. 17A and 17B. Generally, the mouthpiece 304 is configured to eject the cartridge 306 from the distal end of the device 300 via opening 315. Specifically, a user can slide the mouthpiece 304 forward (i.e., towards the distal end of the device 300) so that the second end 304b of the mouthpiece 304 engages the cartridge 306 pushing it forward and disengaging the cartridge from the retention mechanism 376. After which, the cartridge 306 may be pulled out or allowed to drop out of the device 300.

FIG. 17A depicts the device 300 prior to ejection, where the mouthpiece 304 and translating mechanism 387 and are biased outwardly from the receptacle 338 into the closed configuration via biasing mechanism 339. As shown, the proximal end of the cartridge 306 engages the retention mechanism 376, which is configured to retain the cartridge in the receiving chamber 310. In some implementations, the mechanism 376 is a silicone seal configured to frictionally and/or sealingly engage the cartridge so that when the cartridge 306 is pushed into and fully received within the receiving chamber 310, the cartridge 306 is temporarily “locked” in place.

As shown in FIG. 17B, the mouthpiece 304 is actuated (i.e., moved forward into the ejecting position) so that the elongate portion 305 of the mouthpiece 304 enters into the receiving chamber 310 and engages the cartridge 306. In some implementations, the user applies a force B to the enlarged portion 307 of the mouthpiece with their thumb, compressing the biasing mechanism 342 and ejecting the cartridge 306. As the mouthpiece 304 is moved forward, the elongate portion 305 thereof pushes the cartridge forward so that the cartridge 306 becomes disengaged from the cartridge retention mechanism 376. Travel in the forward or second direction is limited by the cavity 389 disposed within the translating mechanism 387, as the enlarged portion 307 is too large to pass through the passageway 383. In the depicted implementation, the biasing mechanism 342 disposed within the cavity 389 is configured to apply an outward force on the enlarged portion 307 of the mouthpiece 304 so as to return the mouthpiece 304 to its neutral position (i.e., the enlarged portion 307 disposed outside of the cavity 389) after the cartridge is ejected and the mouthpiece is released. Alternatively, the mouthpiece 304 may be manually returned to its neutral position.

With reference to FIGS. 18A-18C, in the lighting/use position, the distal end of the cartridge 306 is located proximate the distal end of the holder 302 such that the cartridge 306 is located inside of the receiving chamber 310. In particular, in the lighting/use position of the depicted implementation, the heat source 320 portion of the cartridge 306 is also positioned proximate the distal end of the holder 302 and aligned with the ignitor contacts 328 in the lighting position (see FIG. 14). The heat source 320 is ignited via the aligned push buttons 340 disposed on the opposite sides of the holder 302 of the aerosol delivery device 300. The buttons 340 are movably coupled to the holder 302, with or without a sealing arrangement, so that a user may depress both buttons simultaneously (e.g., via a pinching action) so as to engage and deflect the contact arms 326 and by extension move the ignitor contacts 328 into contact with the ignitable heat source 320. Once released, the buttons 340 return to their original position, at least in part via a spring action from the deflected contact arms 326 and/or a return biasing element. The device 300 includes a pair of LEDs 341 (see FIG. 18C) that may illuminate during ignition and/or change colors to indicate a state of the device 300.

FIGS. 18A and 18B depict distal end views of the aerosol delivery device 300 that further illustrate actuation of the ignitor contacts 328. Specifically, FIG. 18A depicts the ignitor contacts 328 in a first, unactuated position where the ignitor contacts 328 are positioned near, but not in contact with, the ignitable heat source 320. As can be seen through the opening 315 in the distal end of the holder 302, there are two openings 321 (only one is shown) through which the elongate bodies 326 extend. Two spring loaded buttons 340 are disposed on opposing sides of the holder 302 and each extends slightly above an outer surface of the holder. The buttons 340 are oriented proximate the elongate bodies 326 and configured to contact the elongate bodies 326 when pressed. Also depicted is a charging port 319.

FIG. 18B depicts the ignitor contacts 328 in a second, actuated position where the contacts 328 are in contact with the ignitable heat source 320. As shown, the spring loaded push buttons 340 are simultaneously pressed to activate ignition. Specifically, when the buttons 340 are pressed, power is activated and the ignitor contacts 328 are pushed into contact with the ignitable heat source 320 to ignite the heat source 320. Releasing the buttons 340 terminates power and the ignitor contacts pull away from tip automatically (e.g., return to their first position). In various implementations, the device 300 may be programmed so that the ignitor contacts are de-energized after the push button 340 is released and/or after a set period of time (e.g., 30 seconds). Similarly, the contacts 328 may be energized as long as the button 340 is depressed or for a set period of time, for example, a time sufficient for ignition to be achieved. The LEDs 341 on both sides illuminate when the buttons 340 are pressed, although in other implementations, the LEDs may illuminate and/or change colors to indicate a status of the device.

FIGS. 19A, 19B, and 20 illustrate yet another example implementation of an aerosol delivery device 400. In particular, FIGS. 19A and 19B illustrate a perspective view and a cross-sectional perspective view, respectively, of an aerosol delivery device 400 that includes a removable cartridge 406, and a rotating bottom access door 488 for loading and removing the cartridge 406. FIG. 20 provides an exploded view of the aerosol delivery device 400. The aerosol delivery device 400 includes a holder 402 comprising a main body defining a proximal end 402a and a distal end 402b, the main body further defining a receiving chamber 410 configured to receive the removable cartridge 406 therein and a first aerosol passageway 450 that extends through at least a portion of the main body. The cartridge 406 includes an ignitable heat source 420 and a substrate portion 422 comprising an aerosol precursor composition configured to form an aerosol upon application of heat thereto.

The device 400 further includes a mouthpiece 404 having a first end 404a and a longitudinally opposed second end 404b with a second aerosol passageway 454 extending longitudinally therebetween. The first end is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the holder 402. The mouthpiece 404 is configured to sealingly engage with the proximal end 402a of the holder so that the first and second aerosol passageways 450, 454 are in fluid communication so as to deliver the aerosol generated in the receiving chamber to the user. The mouthpiece 404 may be removably coupled to the holder 402 to, for example, provide for cleaning or customization of the device 400. However, in other implementations, the mouthpiece 404 may be integrally formed with the holder 402.

The device 400 further includes the access door 488 pivotably coupled to the distal end 402b of the main body via a hinge mechanism 485. The hinge mechanism 485 may include a pivot arm 484 extending from the door 488 and coupled to the holder 402 via a pivot pin 480. The door 488 provides access to the receiving chamber 410 for loading the removable cartridge 406 therein in an open configuration and, in a closed configuration, secures the removable cartridge in the receiving chamber for ignition thereof. The access door 488 may be moved between the open and closed configuration by “flipping” the door with, for example, a user's thumb. In some implementations, the door 488 is coupled to the holder 402 via a detent hinge configured to maintain the access door 488 in at least one of the open configuration or the closed configuration. The device 400 may further include a biasing mechanism 442 disposed within the main body 402 and configured to interact with the door 488 or hinge assembly 485 to bias the access door into the open and/or closed configuration.

The access door 488 defines an opening 415a therein to provide for access to air/oxygen for an ignited heat source 420. In some implementations, the opening 415a is configured to provide a view of the ignitable heat source portion 420 of the cartridge. In some implementations, a portion of the door 488 may be transparent or translucent to make ignition of the heat source portion 420 viewable during use. For example, the door 488 may include a transparent end cap 414. Additionally, the door may sealingly engage the distal end of the main body in the closed configuration and/or include a latching mechanism (not shown) configured to secure the access door 488 in the closed configuration. In some implementations, the biasing mechanism 442 comprises a spring assembly including a cam 489 that transfers a retaining force to the hinge 485 via the pivot arm 484 to maintain the door 488 in the closed configuration and/or the open configuration.

The holder 402 also houses a power source 412, first and second PCBs 418a, 418b with associated electronics, including a controller, and a pair of ignitor contacts 428 in electrical communication with the power source 412. The contacts 428 may be bar type contacts and are disposed proximate to or at least partially within the opening 415a in the access door 488 and configured to engage the ignitable heat source when the removable cartridge 406 is loaded within the receiving chamber 488 and the door is in the closed configuration, as described in greater detail with respect to FIGS. 21A-21C. The device 400 further includes an ignition switch 440 in electrical communication with the power source 412 and the ignitor contacts 428 and configured to provide power to the contacts when actuated. In some implementations, the ignition switch 440 includes an associated LED indicator 441, for example, a ring encircling the button 440. In some implementations, the second PCB 418b may include a charging port 419 disposed thereon and oriented so that the charging port is disposed at the distal end of the holder 402 (e.g., under the access door 488 as shown in FIG. 22). In some implementations, the opening 415a may include a guard configured to prevent a user from inadvertently contacting the ignitor contacts 428 and/or the ignitable heat source 420.

In the depicted implementation, the device 400 includes an inner housing 424 disposed within the holder 402 and configured to house or secure various components therein. For example, the inner housing 424 may include a plurality of cavities 423 sized and shaped to receive at least portions of the power source 412, the first PCB 418a, the second PCB 418b, the biasing mechanism 442, and/or the hinge mechanism 485. Additionally, the inner housing defines at least a portion of the first aerosol passageway 450 and a receptacle 438 that at least partially defines the receiving chamber 410, which is accessible via a second opening 415b aligned with the opening 415a in the access door 488 and end cap 414 (see also FIGS. 21A-21C).

FIG. 22 further illustrates the structure and connection of the holder 402 and the access door 488, where the access door is in the open configuration. As shown in the depicted implementation, the distal end of the main body 402 and the access door 488 each comprise a mating half of an electrical coupling 425, 429. Specifically, the distal end of the main body comprises at least one electrical contact (e.g., pogo pins) 429 in electrical communication with the power source 412 and the access door 488 comprises at least one mating electrical contact (e.g., insert molded pins) 425 in electrical communication with the ignitor contacts 428, wherein the electrical contacts 425, 429 complete an electrical circuit when the access door is in the closed configuration. The electrical circuit is disrupted when the access door is in the open configuration. Also shown in FIG. 22 is the charging port or connection 419 (e.g., a micro-USB port), which extends through the inner housing 424 and is accessible for charging when the door is in the open configuration.

The operation of the device 400 is generally described with respect to FIGS. 21A-21C, 23A-23B, and 24, which illustrate a series of views of the aerosol delivery device 400 in various states of operation. Specifically, FIG. 21A represents the cartridge 406 being loaded into the device 400 (i.e., access door 488 in the open configuration), FIG. 21B represents the device 400 during ignition and use (i.e., access door 488 in the closed configuration), and FIG. 21C represents the cartridge 406 being ejected from the device 400 (i.e., access door 488 in the open configuration).

Referring to FIGS. 21A, 23A, and 23B, in order to load the cartridge into the receiving chamber 410, the bottom access door 488 is flipped or otherwise actuated into the open configuration, exposing the receiving chamber 410 (see FIG. 23A). The cartridge 406 is manually inserted in the receiving chamber 410 of the holder 402, substrate portion 422 first and guided within the chamber 410 via the guide mechanism 476, so as to locate the cartridge 406 into a lighting and/or use positon. Generally, the guide mechanism 476 is a polymeric element with a tapered internal space that guides the cartridge 406 into place. In some implementations, the guide mechanism 476 may also provide a slight frictional engagement to loosely maintain the cartridge within the receiving chamber 410. The guide mechanism 476 is disposed within the receptacle 438 of the inner housing 424. As shown in FIG. 21B, the inner housing 424 is divided into the receptacle 438 defining at least a portion of the receiving chamber and a cavity defining at least a portion of the first aerosol passageway 450, with a wall 413 disposed therebetween. The wall 413 includes a hollow stem 417 or nozzle disposed therein that fluidly couples the receiving chamber 410 with the first aerosol passageway 450. Disposed between the guide mechanism 476 and the wall 413 is a seal 439, which, in the depicted implementation, also comprises another biasing mechanism configured to maintain the removable cartridge 406 in contact with the ignitor contacts 428 when the door 488 is in the closed configuration, as described below.

With reference to FIG. 21B, after loading the cartridge into the lighting/use position and closing the door 488, the cartridge 406 is disposed within the receiving chamber 410 and in contact with the seal 439, with the ignitable heat source portion in contact with the ignitor contacts 428. The seal in the depicted implementation is a silicone disk seal 439 that acts as a spring insofar as the seal is resiliently compressible. Specifically, when the door is closed, the cartridge engages and compresses the seal 439 so as to seal the cartridge 406 with the aerosol passageway 450 to prevent aerosol leakage or air ingress therebetween, while also applying a force to the cartridge to “push” the ignitable heat source 420 into contact with the ignitor contacts 428. In some implementations, the seal 439 comprises a spring washer covered with a polymeric material. With the ignitable heat source 420 in contact with the ignitor contacts 428, the heat source 420 of the cartridge may be ignited. Heat from the heat source 420 may then heat the substrate material to generate aerosol to be delivered to the user via the aerosol passageways. After the cartridge 406 is consumed, the cartridge 406 may be ejected from the device 400 as described below.

In the depicted implementation, the ignitor push button 440, when pressed by a user, activates the ignitor contacts 428 thereby igniting the heat source 420 of the cartridge 406. Specifically, once the push button 440 is actuated, the electrical circuit is completed and electricity is delivered to the ignitor contacts 428. In some implementations, the ignitor contacts 428 will only remain activated while the ignitor push button 440 is depressed. As such, in some implementations, the ignitor contacts 428 will be deactivated when the ignitor push button 440 is released. In some implementations, the ignitor push button 440 may be configured to activate the ignitor contacts 428 for a set time after release. In one implementation, the push button 440 is disposed on the side of the aerosol delivery device 400. In some implementations, the button 440 may be spring loaded so as to return to an off position after igniting the heat source 420. In other implementations, the button 440 is a “touch” or “soft” button that does not require physical actuation. The device 400 may include a LED 441 that may illuminate during ignition and/or change colors to indicate a state of the device 400. Additionally, a user may be able to observe ignition via the opening 415a.

In use, for example, when a user draws on the holder 402 (e.g., via the mouthpiece 404), ambient air may be drawn into the cavity 438 via the opening 415a, travel through the cartridge 406 (e.g., via the heat source 420) where the air mixes with the aerosol produced by the cartridge, and then travels through the first and second aerosol passageways 450, 454 for inhalation by the user (i.e., vapor path 443). Specifically, the aerosol mixture exiting the cartridge 406 enters the first aerosol passageway 450, which extends a substantial length of the main body 402. The first aerosol passageway 450 is in fluid communication with the second aerosol passageway 454 within the mouthpiece 404, so that the vapor is delivered to the user via opening 458 in the mouthpiece portion 404. In some implementations, the door 488 engages the holder 402 via a gasket or other sealing mechanism so that there is no aerosol leakage or air ingress therebetween, other than through the opening 415a.

Ejection of the cartridge 406 is shown in FIGS. 21C and 24. Generally, the device 400 is configured to eject the cartridge 406 from the distal end 402b of the holder via opening 415b in the inner housing 424 when the access door 488 is in the open configuration. Once the door 488 is rotated into the open configuration, the electrical connectors 425, 429 are separated and the electrical circuit disrupted, thereby preventing inadvertent electrification of the ignitor contacts 428. In addition, as described above, one end of the cartridge 406 loosely engages the guide mechanism 476, which is otherwise held in place by the door 488 in the closed configuration, so that once the door is opened, the cartridge should just fall out when the device 400 is oriented downwardly. In some implementations, the biasing force of the seal 439 may assist with ejecting the cartridge 406 (e.g., the force may be sufficient to overcome any frictional engagement between the cartridge and the guide mechanism 476). After ejection, a user may insert a new cartridge or simply close the access door 488 and store the device 400 for later use. In some implementations, the device 400 may include a latching mechanism (not shown) configured to further secure the access door 488 in the closed configuration. In some implementations, the latching mechanism may include a magnetic engagement, a snap-fit, a detent, and/or be spring-loaded into the closed configuration.

FIGS. 25A, 25B, and 26 illustrate another example implementation of an aerosol delivery device 500. In particular, FIGS. 25A and 25B illustrate a perspective view and a cross-sectional side view, respectively, of an aerosol delivery device 500 that includes a removable mouthpiece 504. Specifically, the aerosol delivery device 500 comprises a holder 502 having a main body defining a proximal end 502a and a distal end 502b, where the holder 502 further defines a receiving chamber 510 configured to receive a removable cartridge (506 in FIG. 26) and a first aerosol passageway 550 that extends through at least a portion of the main body. In some implementations, the removable cartridge 506 comprises an ignitable heat source 520 and a substrate portion 522 that includes a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat thereto (see FIG. 26). The holder 502 further comprises an access door 588 that may be slidingly or hingedly coupled to the holder 502 and configured to be opened for loading the cartridge 506 into the receiving chamber 510 via an opening or receptacle 538 in the inner housing 524 (see FIG. 27A). The device further includes an actuator assembly 508 configured to eject the cartridge from the device as described below.

As further illustrated by the exploded view of FIG. 26, the device 500 includes an inner housing 524 disposed within the holder 502 and further defining the receiving chamber 510 and the opening 538 for receiving the cartridge 506. A proximal end of the inner housing 524 includes a retention mechanism 569 configured to engage with the mouthpiece 504 as described below. The inner housing 524 includes a tubular structure 525 disposed therein and extending along a length of the housing 524. The tubular structure 525 defines the first aerosol passageway 550 and extends partially beyond the proximal end of the inner housing 524 and is configured to engage at least a portion of the mouthpiece 504 to provide fluid communication between the first and second aerosol passageways 550, 554 and deliver the aerosol to a user via an opening 558 in the mouthpiece 504. The receiving chamber 510 of the device 500 is further defined by an end cap 514 engaged with the distal end 502b of the holder 502 and defining an opening 515 configured to pass the removable cartridge 506 therethrough when ejected, as opposed to removing the cartridge via the loading opening 538. The actuator assembly 508 is slidably disposed within the main body of the holder 502 and configured to eject the cartridge 506 when slid forward towards the distal end of the holder 502. In some implementations, the actuator assembly 508 is spring-loaded so as to return the actuator assembly 508 to a neutral position. The cartridge 506 may be removably secured within the receiving chamber 510 and sealed relative to the first aerosol passageway 550 via any of the mechanisms or manners disclosed herein (e.g., frictionally engaged via an elastomeric seal).

The device 500 further includes a power source 512 and a printed circuit board 518 disposed within the inner housing 524. The power source 512 is in electrical communication with the printed circuit board 518 and a pair of static ignitor contacts 528 disposed thereon that may be energized via a push button 540 disposed on a side wall of the holder 502. Specifically, once the push button 540 is actuated, the electrical circuit is completed and electricity is delivered to the ignitor contacts 528. In various implementations, the device 500 may be programmed so that the ignitor contacts 528 are de-energized after the push button 540 is released and/or after a set period of time (e.g., 50 seconds). Similarly, the contacts 528 may be energized as long as the button 540 is depressed or for a set period of time, for example, a time sufficient for ignition to be achieved. The ignitor contacts 528 may be coupled to the printed circuit board via one or more flexible arms 526 that allow the contacts 528 to flex outwardly when the cartridge is inserted therebetween. Specifically, the ignitor contacts 528 are configured to deflect when contacted by the ignitable heat source portion 520 so as to removably secure the ignitable heat source portion therebetween when the removable cartridge is removably secured within the receiving cavity 510 via the opening 538. The printed circuit board 518 may further comprise a charging port 519 that is oriented on the printed circuit board so as to be disposed at one end of the holder 502.

In the depicted implementation, the actuator assembly 508 has an inclined or wedged shaped body 589 with a leading edge 589a oriented so that the leading edge 589a may be inserted between the contact arms 526 and/or the ignitor contacts 528. As the actuator assembly 508 is advanced, the leading edge 589a pushes the contact arms 526 or ignitor contacts 528 outwardly so as to move them out of contact with the ignitable heat source 520 of the cartridge 506, thereby releasing the cartridge. In some implementations the cartridge is then free to fall out of the device 500 when the distal end thereof is angled downwardly. Additionally, or alternatively, a portion of the actuator assembly 508 may also contact the cartridge 506 so as to push the cartridge at least partially out of the opening 515 in the end cap 514.

In the depicted implementation, the mouthpiece 504 has a first end 504a and a longitudinally opposed second end 504b with a second aerosol passageway 554 extending longitudinally therebetween. In the depicted implementation, the mouthpiece 504 is located at the proximal end of the holder 502, with the first end 504a configured to engage with a user's mouth and the second end 504b configured to engage the proximal end of the holder 502. The mouthpiece 504 is configured to sealingly engage with the holder 502 so that the first and second aerosol passageways 550, 554 are in fluid communication so as to deliver the aerosol generated in the receiving chamber to the user. The removable mouthpiece 504 comprises a hollow body 556 (i.e., recess) and a stem 505 (or similar tubular structure) disposed within the hollow body 556 and extending from the first end 504a to the second end 504b. The stem 505 defines the second aerosol passageway 554 extending therethrough and is engaged with the inner housing 524 so as to fluidly couple with the aerosol passageway 550 of the inner housing 524. The stem 505 may be coupled to the inner housing 524 via, for example, a press-fit or snap-fit engagement with the tubular structure 525 within the inner housing 524. In some implementations, the stem 505 is sealingly engaged with the first aerosol passageway 550 in the holder 502. For example, the stem 505 may include a sealing mechanism 559 similar to any of those disclosed herein.

In some implementations, the stem 505 of the mouthpiece 504 is offset from a central axis of the device 500. Specifically, the stem 505 comprises a centrally located longitudinal axis 597b offset from and generally in parallel with a centrally located longitudinal axis 597a of the device 500, such that the stem 505 of the mouthpiece, and the second aerosol passageway 554, is aligned with the first aerosol passageway 550 in the inner housing 524 to define a direct vapor path from the cartridge 506 to the mouthpiece 504. As shown in FIG. 25B, the second aerosol passageway 554 opens into a recess or receptacle 567 disposed within the proximal end of the mouthpiece 504 for delivery of the aerosol to the user. The offset arrangement simplifies the vapor path so as to minimize and/or eliminate loss of vapor (e.g., fewer joints or interfaces results in fewer leak points).

In some implementations, the longitudinally opposed second end 504b of the mouthpiece 504 is configured to engage an opening in the proximal end 502a of the holder via at least one of complementary-threaded surfaces for a screw-type engagement, a press-fit engagement, a snap-fit engagement, or a magnetic engagement. In other implementations, the mouthpiece 504 is removably secured to the holder 502 via a sealing mechanism that provides frictional resistance between the mouthpiece 504 and the holder 502 or other component therein. In some implementations, the inner housing 524 includes a retention structure 569a disposed on a proximal end thereof and the second end 504b of the mouthpiece 504 defines a mating retention structure 569b configured to engage the retention structure 569a on the inner housing 524. The retention structure 569 may be a snap-fit mechanism or other type of reversible coupling mechanism. The retention structure 569 may further removably secure the mouthpiece 504 to the holder 502. The mouthpiece 504 can be removed from the holder 502 for, for example, cleaning or customization of the device 500 (e.g., the use of interchangeable mouthpieces) by, for example, application of a pulling or twisting action to the mouthpiece 504 or actuating a release.

FIGS. 27A and 27B illustrate the loading and ejecting of the cartridge (i.e., consumable) 506 relative to the device 500. Specifically, FIG. 27A depicts the loading path of the cartridge 506 where the access door 588 is slid forward or distally to expose the opening 538 in a sidewall of the holder 502 and inner housing 524. The opening 538 provides access to the receiving chamber 510. The access door 588 may be sealingly coupled to the holder 502 via a track and rail mechanism; however, the door 508 could also be coupled to the holder 502 via a hinge or threaded mechanism, with or without a gasket 516. With the receiving chamber 510 exposed, the cartridge 506 is inserted through the opening 538 and secured therein via the ignitor contacts 528 as described above. Once loaded, the access door 588 is slid back into the closed configuration (FIG. 27B).

In some implementations, the device 500 may include a latching mechanism (not shown) configured to secure the access door 508 in the closed configuration. In some implementations, the latching mechanism may include a magnetic engagement, a threaded interface, a snap-fit, a detent, and/or be spring-loaded into the closed configuration. The door 588 may be flush with an outer surface of the holder 502 when in the closed configuration and may include a raised edge or a knurled (or otherwise textured) surface formed thereon to assist in sliding the door between the open and closed configurations.

FIG. 27B depicts the device 500 in the closed configuration with the access door 588 covering the opening so as to secure the cartridge 506 in fluid communication with first aerosol passageway 550 (see FIG. 25B). In the closed configuration, the ignitable heat source 520 is in contact with the ignitor contacts 528 and may be ignited so that the cartridge may be consumed. After which, the cartridge 506 may be ejected from the device 500 as shown. Specifically, the actuator assembly 508 is slid forward or distally so as to release the cartridge 506 as described above. Once released, the cartridge is free to fall out of the device 500 via opening 515 when the distal end is angled downwardly. The access door 588 remains closed during ejection. When a user is ready to enjoy another cartridge, the door 588 may be slid open again and the process repeated.

FIGS. 28A, 28B, and 29-32 illustrate another example implementation of an aerosol delivery device 600. In particular, FIGS. 28A and 28B illustrate a perspective view and a cross-sectional side view, respectively, of an aerosol delivery device 600 that includes a removable mouthpiece 604. In the depicted implementation, the aerosol delivery device 600 includes a holder 602 comprising a main body defining a proximal end 602a and a distal end 602b and further defining a receiving chamber 610 configured to receive a removable cartridge 606. In some implementations, the removable cartridge 606 comprises an ignitable heat source 620 and a substrate portion 622 that includes a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat thereto.

The device 600 also includes a mouthpiece 604 removably secured to the holder 602. The removable mouthpiece 604 comprises an elongate body portion defined by a first end 604a and a longitudinally opposed second end 604b with an aerosol passageway 654 extending therethrough. The mouthpiece 604 further includes a first retention mechanism 670 disposed about an exterior surface of the elongate body portion and located proximate the first end 604a of the elongate body portion and a second retention mechanism 676 disposed within a receptacle 667 defined by the second end 604b of the elongate body member. The first retention mechanism 670 is configured to removably secure the second end of the mouthpiece 604 within the holder 602 and the second retention mechanism 676 is configured to removably secure a portion of the cartridge 606 therein. The retention mechanisms 670, 676 are described in greater detail with respect to FIGS. 30 and 31. The first end 604a of the mouthpiece 604 is configured to engage with a user's mouth.

As further illustrated by the exploded view of FIG. 29, the device 600 includes an inner housing 624 disposed within the holder 602 and further defining a passageway 613 configured to receive the mouthpiece 604. A proximal end of the inner housing 624 includes a retention mechanism 669 configured to engage with the proximal end 602a of the holder 602. The inner housing 624 includes one or more receptacles 638 disposed therein and configured to retain a power source 612 and/or one or more printed circuit boards 618 therein. The power source 612 is in electrical communication with the printed circuit board 618 and a pair of static ignitor contacts 628 disposed thereon that may be energized via a push button 640 disposed on a side wall of the holder 602. Specifically, once the push button 640 is actuated, the electrical circuit is completed and electricity is delivered to the ignitor contacts 628. In some implementations, the ignitor push button 640 may be configured to activate the ignitor contacts 628 for a set time after release or the ignitor contacts will be deactivated when the ignitor push button is released. The printed circuit board 618 may further comprise a charging port 619 that is oriented on the printed circuit board so as to be disposed at one end of the holder 602. The receiving chamber 610 of the device 600 is further defined by an end cap 614 engaged with the distal end 602b of the holder 602 and defining a plurality of openings 615 (e.g., small perforations) configured to allow air to enter the device 600 and flow through the receiving chamber 610.

FIGS. 30 and 31 depict the retention mechanisms 670, 676 in greater detail. Generally, the mouthpiece 604 is slidably disposed with the holder 602 via the passageway 613 until the distal end 604b thereof engages a stop 674 formed in the inner housing 624. In some implementations, the stop 674 is part of the distal end of the inner housing 624, for example, the opening 613′ in the distal end of the inner housing 624 is of a smaller diameter than the passageway 613 itself, so that the cartridge 606 can pass therethrough, but not the mouthpiece 604. The mouthpiece 604 is retained within the passageway 613 via retention mechanism 670, which sealingly and frictionally engages with the inner surface of the passageway 613 to prevent any leakage of the generated aerosol about the mouthpiece and to provide resistance to inadvertent removal of the mouthpiece 604 from the holder 602 (i.e., the mouthpiece 604 will not fall out of the holder 602 regardless of the orientation of the device 600). In some implementations, the first retention mechanism 670 includes an elastomeric seal disposed about an exterior surface of the mouthpiece 604 (e.g., insert molded thereto). See FIG. 29.

The second end 604b of the mouthpiece 604 is shown in FIG. 30. As shown, the second end 604b defines a receptacle 667 comprising the second retention mechanism 676 disposed therein. Similar to the first retention mechanism 670, the second retention mechanism 676 is configured to sealingly and frictionally engage with the substrate portion of the cartridge 606, which allows the generated aerosol to pass therefrom to the aerosol passageway 654. The proximal end wall of the receptacle 667 defines an opening therethrough 650 that allows the aerosol to pass therethrough, but not the cartridge 606. The second retention mechanism 676 may also include an elastomeric seal disposed about an interior surface of the receptacle 667 and configured to engage with the cartridge 606. In the depicted implementation, the second end 604b of the mouthpiece abuts the stop 674 when fully inserted and positions the cartridge 606 within the receiving chamber 610 so that the ignitable heat source 620 deflects the ignitor contacts 628 open and the ignitable heat source 620 is retained therebetween (see FIG. 28B).

FIGS. 32A-32C illustrate the mouthpiece 604 in use, specifically how the cartridge 606 is loaded into and removed from (i.e., ejected) the holder 602. As shown in FIG. 32A, the mouthpiece 604 has been removed from the holder and is brought into contact with a cartridge 606 secured within a package 699 configured to hold multiple cartridges 606. Once the cartridge 606 is loaded into the recess 667 (see FIG. 31) of the mouthpiece 604 it is retained therein via the second retention mechanism 676 and the mouthpiece 604 and cartridge are withdrawn from the packaging. A user can then insert the loaded mouthpiece 604 into the holder 602 via passageway 613 as shown in FIG. 32B. Once fully inserted, the user can press the ignitor push button 640 to light the ignitable heat source 620 of the cartridge 606. The mouthpiece 604 is retained within the holder 602 via the first retention mechanism 670 until the user decides to remove/replace the cartridge (e.g., after the cartridge is fully consumed). The mouthpiece 604 may be removed by an application of a pulling and/or twisting action thereto to overcome the frictional engagement between the mouthpiece and passageway 613. After removing the mouthpiece 604 from the holder 602, the cartridge may be removed from the mouthpiece by an application of a pulling and/or twisting action thereto to overcome the frictional engagement between the cartridge 606 and the mouthpiece receptacle 667, as shown in FIG. 32C.

FIGS. 33-39C illustrate another example implementation of an aerosol delivery device 700. In particular, FIGS. 33 and 34 illustrate a front view and a side view, respectively, of an aerosol delivery device 700 that includes a removable mouthpiece 704. In the depicted implementation, the aerosol delivery device 700 includes a holder 702 comprising a main body defining a proximal end 702a and a distal end 702b and further defining a receiving chamber 710 configured to receive a removable cartridge 706 (see FIG. 35B). In some implementations, the removable cartridge 706 comprises an ignitable heat source 720 and a substrate portion 722 that includes a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat thereto.

The device 700 also includes a mouthpiece (also referred to herein as a mouthpiece assembly) 704 removably secured to the holder 702. The removable mouthpiece 704 is configured to engage the proximal end of the holder 702 and may be held therein via a retention mechanism, such as, for example, magnets 727 (see FIG. 38). The mouthpiece 704 is described in greater detail with respect to FIGS. 36-37C. The mouthpiece 704 comprises a first portion 707 comprising an elongate body defined by a first end 707a and a longitudinally opposed second end 707b with a passageway 713 extending therethrough and a second portion 805 defined by a first end 705a and a longitudinally opposed second end 705b with a first aerosol passageway 754 extending therethrough. The first end of the second portion 705 is configured to engage with a user's mouth and the second end 705b is partially disposed within the passageway 713 of the first portion 707 of the mouthpiece 704 proximate the first end 707a of the first portion of the mouthpiece 704.

The mouthpiece assembly 704 further includes a slider body 730 defined by a first end 830a and a longitudinally opposed second end 730b with a second aerosol passageway 750 extending therethrough. The slider body 730 is slidably disposed within the first portion of the mouthpiece 707 and the first end 730a of the slider body 730 is coupled to the second end 705b of the second portion 705 of the mouthpiece 704 (e.g., via a retention mechanism 769 similar to any of those disclosed herein) and the second end 730b of the slider body 730 is configured to engage the removable cartridge 706. The second portion 705 of the mouthpiece 704 is configured to sealingly engage with the slider body 730 so that the first and second aerosol passageways 750, 754 are in fluid communication so as to deliver the aerosol generated in the receiving chamber to the user via outlet 758. In the depicted implementation, the second end 730b of the slider body comprises a stem 733 configured to engage with and eject the removable cartridge 706 upon application of a force to the second portion 705 of the mouthpiece. The slider body 730 is also configured to slidably engage an inner tubular body 703 via, for example, one or more projections 779a disposed about an outer surface of the slider body 730 and mating with one or more slots 779b disposed in a wall of the inner tubular body 703. The slider body 730 may be configured to slide along a length of the first portion 707 of the mouthpiece 704 in a first direction and a second direction.

The inner tubular body 703 is defined by a first end 703a and a longitudinally opposed second end 703b and configured to slidably receive the slider body 730 therein. The inner tubular body 703 further defines a receptacle 738 therein that is sized and shaped to retain a first biasing mechanism 739 therein. The second end 703b of the inner tubular body 703 is configured to engage the first portion 707 of the mouthpiece proximate the second end 707b thereof. For example, the inner tubular body 703 may be configured to engage an inner surface of the first portion 707 of the mouthpiece 704 via at least one of complementary-threaded surfaces for a screw-type engagement, a press-fit engagement, a snap-fit engagement, or a magnetic engagement. The receiving chamber 710 of the device 700 is at least partially defined by an outlet guide 746 coupled to the second end 707b of the first portion of the mouthpiece 704 and partially received within the second end 703b of the inner tubular body 703. The outlet guide 746 defines a cavity 710′ configured to sealingly engage and removably secure the removable cartridge 706 therein via a retention mechanism 776 (e.g., an O-ring 860) disposed therein.

The first biasing mechanism 739 is configured to maintain the mouthpiece assembly 704 in a loading configuration. Specifically, the slider body 730 is biased towards the first end 707a of the first portion 707 of the mouthpiece 704 so that the cartridge may be loaded into and secured within the outlet guide 746 (see FIGS. 37A and 37B). To eject the cartridge 706 from the mouthpiece assembly 704, a user applies a force to (i.e., pushes down on) the second portion 705 of the mouthpiece assembly, which pushes the slider body 730 against the first biasing mechanism 739. The first biasing mechanism 739 is compressed within the inner tubular body 703, so that the stem 733 engages the cartridge 706 and pushes it out of and beyond the retention mechanism 776 (see FIG. 37C). Once the cartridge 706 is disengaged from the retention mechanism 776, it is free to slid out of the mouthpiece 704.

The holder 702 (also referred to herein as the holder assembly) is depicted in greater detail on FIGS. 35A, 35B, and 38. As illustrated by the exploded view of FIG. 38, the device 700 includes an inner housing 724 disposed within the holder 702 and defining one or more receptacles or cavities 767 defined therein and configured to retain a power source 712 and/or one or more printed circuit boards 718 therein. In some implementations, the inner housing 724 comprises two-pieces 724a, 724b coupled together (e.g., via a snap-fit). The holder 702 further comprises an outer tubular body 703′ disposed within a first one of the receptacles 767 and defining an interior cavity configured to slidably receive the mouthpiece assembly 704 therein. The mouthpiece 704 may be retained therein via magnetic engagement. The holder includes two end caps 714, 714′ disposed at opposite ends thereof. Specifically, a first end cap 714′ is coupled to the proximal end 702a of the holder and defines a first opening 715′ in communication with the interior cavity of the outer tubular body 703′ and a second end cap 714 is coupled to the distal end 702b of the holder and defines a second opening 715 in communication with the interior cavity of the outer tubular body 703′. One or both of the end caps 714, 714′ may be configured to secure at least one of the inner housing 724 or the outer tubular body 703′ within the holder. In some implementations, the ends of the inner housing 724 may include retention mechanisms 769 configured to engage with the ends of the holder 702 and/or end caps 714, 714′. In one example implementation, the end caps 714, 714′ are secured to the holder 702 via set screws 762.

The receiving chamber 710 of the device 700 is further defined by the second end cap 714, where the opening 715 is configured to allow air to enter the device 700 and flow through the receiving chamber 710/cartridge 706. The holder 702 further comprises a pair of ignitor contacts 728 disposed within the receiving chamber 710 proximate the distal end of the holder and spanning across the opening 715 in the second end cap 714. A second biasing mechanism 742 is disposed within the main body of the holder 702 and configured to engage a distal end of the mouthpiece 704 when the mouthpiece is inserted within the holder so as to position the ignitable heat source 720 of the cartridge 706 away from the ignitor contacts 728. In the depicted implementation, the second biasing mechanism 742 comprises a return spring engageable with a collar 752 slidably disposed within the outer tubular body 703′ via, for example, one or more projections 779a disposed about an outer surface of the collar 752 and mating with one or more slots 779b disposed in a wall of the outer tubular body 703′. A distal end of the collar 752 is configured to engage the return spring. In some implementations, the second end cap 714 further comprises a standoff 789 extending into the inner housing 724 and also partially defining the receiving chamber 710. The standoff 789 defines a pair of opposing slots configured to secure the ignitor contacts 728 therein so as to be engageable with the ignitable heat source 720 as described below.

The power source 712 is in electrical communication with the printed circuit board 718 and the static ignitor contacts 728, which may be energized via a push button 740 disposed on a side wall of the holder 702. Specifically, once the push button 740 is actuated, the electrical circuit is completed and electricity is delivered to the ignitor contacts 728. In some implementations, the ignitor push button 740 may be configured to activate the ignitor contacts 728 for a set time after release or the ignitor contacts will be deactivated when the ignitor push button is released. The printed circuit board 718 may further comprise a charging port 719 that is oriented on the printed circuit board so as to be disposed at one end of the holder 702.

Operation of the aerosol delivery device 700 is further described with respect to FIGS. 39A-39C. Generally, the mouthpiece assembly 704 may have a cartridge 706 loaded therein in a similar manner to aerosol delivery device 600 depicted in FIG. 32A. As shown in FIG. 39A, the user can insert the loaded mouthpiece 704 into the holder 702 via the opening 715′ (see FIG. 38). Once fully inserted, the user can press the ignitor push button 740 to arm or otherwise activate the ignitor contacts 728 as shown in FIG. 39B. In this neutral configuration, the ignitable heat source 720 of the cartridge 706 does not contact the ignitor contacts 728, because the second biasing mechanism 742 biases the mouthpiece 704 away from the distal end of the holder 702. The user then pushes the mouthpiece 704 into the holder 702 so as to overcome the resistance of the second biasing mechanism 742 and move the ignitable heat source 720 into contact with the energized ignitor contacts 728 as shown in FIGS. 39C and 35B. If the mouthpiece 704 is pushed in before the contacts 728 are armed, the heat source 720 will not ignite.

In some implementations, a LED 741 associated with the push button 740 is illuminated when the ignitor contacts 728 are energized and may change state (e.g., flashing to solid, different colors or intensity, etc.) when the cartridge 706 is brought into contact with the ignitor contacts 728. In various implementations, the device 700 may be programmed so that the ignitor contacts are de-energized after the push button 740 is released, after a set period of time (e.g., 30 seconds), and/or after a set period of time if the contacts 728 are not bridged by the ignitable heat source 720 portion of the cartridge 706 (e.g., 10 seconds). The LED 741 may also be configured to indicate various other states of operation (low power, charging, etc.) by, for example, changing colors, flashing, etc.

The mouthpiece 704 is retained within the holder 702 via the magnets 727 until the user decides to remove/replace the cartridge (e.g., after the cartridge is fully consumed). The mouthpiece 704 may be removed by an application of a pulling action thereto to overcome the magnetic engagement between the mouthpiece 704 and holder 702. After removing the mouthpiece 704 from the holder 702, the cartridge may be ejected by pressing down on the second portion 705 of the mouthpiece (see FIG. 37C), which moves the slider body 730 distally until the stem 733 engages the cartridge 706 pushing it distally out of the outlet guide 746. After the cartridge is ejected and the force removed from the second portion 705 of the mouthpiece, the first biasing mechanism 739 will return the slider body 730 to a loading configuration. The first biasing mechanism 739 comprises an ejection spring that has a greater spring force than the return spring of the second biasing mechanism 742 so as to prevent accidental ejection of the cartridge 706 when igniting the cartridge 706, as the second biasing mechanism 742 will be actuated prior to the first biasing mechanism 739 due to the difference in spring forces.

In some implementations, the mouthpiece assembly 704 may be removed from the holder 702 after ignition thereof so that the user only needs to hold onto the mouthpiece assembly 704. Alternatively, or additionally, the cartridge 706 may be manually lit so as to eliminate the need for the holder 702 in certain circumstances.

In the depicted implementations, the outer housing or holder may comprise a rigid material. For example, the holders 102, 202, 302, 402, 502, 602, 702 of the depicted implementations may be constructed of an aluminum material; however, in other implementations, the holders may be constructed of other materials, including other metal materials (such as, for example, stainless steel, aluminum, brass, copper, silver, gold, bronze, titanium, various alloys, etc.), or graphite materials, or ceramic materials, or plastic materials, or any combinations thereof. In some implementations, at least a portion of the heat source and/or at least a portion of the substrate material may be circumscribed by a paper foil laminate. In some implementations, the cartridge may comprise an enclosure comprising a laminate that contains a heat source and a beaded substrate material. Some examples of laminates and/or enclosures that may be applicable to the present disclosure can be found in U.S. Pat. App. Pub. No. 2020/0128880 to Gage et al., which is incorporated herein by reference in its entirety. Other examples of cartridges are described herein below with respect to FIGS. 40 and 41.

In some implementations, the holder (or any components thereof) may be made of moldable plastic materials such as, for example, polycarbonate, polyethylene, acrylonitrile butadiene styrene (ABS), polyamide (Nylon), or polypropylene. In other implementations, the holder may be made of a different material, such as, for example, a different plastic material, a metal material (such as, but not limited to, stainless steel, aluminum, brass, copper, silver, gold, bronze, titanium, various alloys, etc.), a graphite material, a glass material, a ceramic material, a natural material (such as, but not limited to, a wood material), a composite material, or any combinations thereof. The holders may be formed via extrusion. As noted above, the mouthpiece portion of some implementations is separable from the main body, while in other implementations, the mouthpiece portion may be integral with the main body. In any event, the mouthpiece portion and the main body may be made of the same material or different materials. In various implementations comprising a separable mouthpiece portion, the mouthpiece portion may be coupled to the main body in a variety of ways, including, for example, via one or more of a snap-fit, interference fit, screw thread, magnetic, and/or bayonet connection. In other implementations, the mouthpiece portion may be integral with the main body and thus may not be separable.

In the depicted implementations, the holder includes walls that are substantially solid and non-porous; however, in other implementations one or more of these walls of a holder may have other configurations. For example, in some implementations one or more of the walls of a holder may be non-solid and/or substantially porous or may include one or more non-solid and/or substantially porous portions. In some implementations, for example, the holder may include one or more apertures that may facilitate access of oxygen to the heat source. Alternatively, or additionally, other implementations may include one or more apertures that may mix with the aerosol generated during a draw. In such a manner, in the use position the one or more apertures may be located proximate the heat source, thus providing the heat source with additional access to oxygen during combustion. In some implementations, the holder may include one or more apertures downstream from the heat source. For example, in some implementations the holder may include apertures that extend into the aerosol passage of the holder that may mix with aerosol generated by the substrate material of the cartridge.

As described above, the holder of various implementations of the present disclosure includes a lighting/use position. In some implementations, the holder may also have an extinguishment position. In such a manner, the extinguishment position may be configured such that the heat source of a cartridge is deprived of sufficient oxygen to sustain combustion. In some implementations, the extinguishment position may be obtained by a further action of the holder. In other implementations, one or more additional features may be included such that an extinguishment position may be achieved by translating the one or more additional features. In particular, the holder of one implementation may include an air impermeable cover feature located proximate the distal end of the holder that may be mechanically or manually actuatable (e.g., by rotating the cover feature over the end of the main body and/or by sliding the cover feature across the end of the main body) such that in the extinguishment position, the cover feature substantially covers the open end of the holder and the heat source of the cartridge is deprived of sufficient oxygen to sustain combustion. In another implementation, the holder may include a detachable feature, such as, for example, an end cap, that may be used to achieve the extinguishment position. For example, in some implementations a separate end cap may be attachable over the distal end of the holder such that, once attached, the heat source of the cartridge is deprived of sufficient oxygen to sustain combustion. Such an end cap could also be used to cover the end of the second body portion when not in use, such as, for example, to prevent dirt and/or foreign objects from entering into the device. Additionally, or alternatively, in some implementations the holder of the present disclosure may include an air permeable cover feature (e.g., a cover feature comprising a plurality of openings or a cover feature comprising a mesh) that protects the heat source of the cartridge in the lighting/use position. For example, the holder of one implementation may include an air permeable cover feature located proximate the distal end of the holder that may be mechanically or manually actuatable (e.g., by rotating the cover feature over the end of the holder and/or by sliding the cover feature across the end of the holder) such that once ignited, the cover feature may be actuated to substantially cover the open end of the holder while maintaining sufficient access of oxygen to the heat source.

In various implementations, a removable cartridge may have other configurations for use with a holder of the present disclosure. For example, FIG. 40 illustrates a perspective view of a removable cartridge 806, according to another example implementation of the present disclosure. In the depicted implementation, the cartridge 806 defines a proximal end 890 and a distal end 892. The cartridge 806 of the depicted implementation further includes an ignitable heat source 820, which comprises a fuel element 894, a substrate portion 822, which comprises a substrate material 896 (see FIG. 41), and an outer housing 898 configured to circumscribe at least a portion of the ignitable heat source 820 and the substrate material 822. It should be noted that although in the depicted implementation the cartridge 806 has a substantially cylindrical overall shape, in various other implementations, the cartridge or any of its components may have a different shape. For example, in some implementations the cartridge (and/or any of its components) may have a substantially rectangular shape, such as a substantially rectangular cuboid shape. In other implementations, the cartridge (and/or any of its components) may have other hand-held shapes. Some examples of cartridge configurations that may be applicable to the present disclosure can be found in U.S. Pat. App. Pub. No. 2021/0015173 to Cox et al., which is incorporated herein by reference in its entirety.

In some implementations, a barrier may exist between the heat source and the substrate material. In some implementations, such a barrier may comprise a disc that may include one or more apertures therethrough. In some implementations, the barrier may be constructed of a metal material (such as, for example, stainless steel, aluminum, brass, copper, silver, gold, bronze, titanium, various alloys, etc.), or a graphite material, or a ceramic material, or a plastic material, or any combinations thereof. In some implementations, a heat transfer component, which may or may not comprise a barrier, may exist between the heat source and the substrate material. Some examples of heat transfer components are described in U.S. Pat. App. Pub. No. 2019/0281891 to Hejazi et al., which is incorporated herein by reference in its entirety. In some implementations, a barrier and/or a heat transfer component may prevent or inhibit combustion gasses from being drawn through the substrate material (and/or from being drawn through air passageways through which aerosol is drawn).

In various implementations, the heat source may be configured to generate heat upon ignition thereof. In the depicted implementation, the ignitable heat source 820 comprises a combustible fuel element 894 that has a generally cylindrical shape and that incorporates a combustible carbonaceous material. In other implementations, the heat source may have a different shape, for example, a prism shape having a cubic or hexagonal cross-section. Carbonaceous materials generally have a high carbon content. Some carbonaceous materials may be composed predominately of carbon, and/or typically have carbon contents of greater than about 60 percent, generally greater than about 70 percent, often greater than about 80 percent, and frequently greater than about 90 percent, on a dry weight basis.

In some instances, the heat source may incorporate elements other than combustible carbonaceous materials (e.g., tobacco components, such as powdered tobaccos or tobacco extracts; flavoring agents; salts, such as sodium chloride, potassium chloride and sodium carbonate; heat stable graphite a hollow cylindrical (e.g., tube) fibers; iron oxide powder; glass filaments; powdered calcium carbonate; alumina granules; ammonia sources, such as ammonia salts; and/or binding agents, such as guar gum, ammonium alginate and sodium alginate). In other implementations, the heat source may comprise a plurality of ignitable objects, such as, for example, a plurality of ignitable beads. It should be noted that in other implementations, the heat source may differ in composition or relative content amounts from those listed above. For example, in some implementations different forms of carbon could be used as a heat source, such as graphite or graphene. In other implementations, the heat source may have increased levels of activated carbon, different porosities of carbon, different amounts of carbon, blends of any above mentioned components, etc. In still other implementations, the heat source may comprise a non-carbon heat source, such as, for example, a combustible liquefied gas configured to generate heat upon ignition thereof. For example, in some implementations, the liquefied gas may comprise one or more of petroleum gas (LPG or LP-gas), propane, propylene, butylenes, butane, isobutene, methyl propane, or n-butane. In still other implementations, the heat source may comprise a chemical reaction based heat source, wherein ignition of the heat source comprises the interaction of two or more individual components. For example, a chemical reaction based heat source may comprise metallic agents and an activating solution, wherein the heat source is activated when the metallic agents and the activating solution come in contact. Some examples of chemical based heat sources can be found in U.S. Pat. No. 7,290,549 to Banerjee et al., which is incorporated herein by reference in its entirety. Combinations of heat sources are also possible. Although specific dimensions of an applicable heat source may vary, in the depicted implementation, the ignitable heat source 820 has a length in an inclusive range of approximately 1 mm to approximately 20 mm, and in some implementations may be approximately 12 mm, and an overall diameter in an inclusive range of approximately 3 mm to approximately 8 mm, and in some implementations may be approximately 4.8 mm (and in some implementations, approximately 7 mm).

Although in other implementations the heat source may be constructed in a variety of ways, in the depicted implementation, the ignitable heat source 820 is extruded or compounded using a ground or powdered carbonaceous material, and has a density that is greater than about 0.5 g/cm³, often greater than about 0.7 g/cm³, and frequently greater than about 1 g/cm³, on a dry weight basis. See, for example, the types of fuel source components, formulations and designs set forth in U.S. Pat. No. 1,551,451 to Riggs et al. and U.S. Pat. No. 7,836,897 to Borschke et al., which are incorporated herein by reference in their entireties.

In various implementations, the heat source may have a variety of forms, including, for example, a substantially solid cylindrical shape or a hollow cylindrical (e.g., tube) shape. In other implementations, the heat source may comprise a plurality of hollow or substantially solid spheres, which in some implementations may comprise substantially the same size, and in other implementations may comprise more than one size. In various implementations, the heat source may be made in variety of ways, including, but not limited to, via extrusion, injection molding, compression molding, etc. The ignitable heat source 820 of the depicted implementation comprises an extruded monolithic carbonaceous material that has a generally cylindrical shape that includes a plurality of internal passages 891 extending longitudinally from a first end of the ignitable heat source 820 to an opposing second end of the ignitable heat source 820. In the depicted implementation there are approximately thirteen internal passages 891 comprising a single central internal passage 891a, six surrounding internal passages 880b, which are spaced from the central internal passages 891a and have a similar size (e.g., diameter) to that of the central internal passage 891a, and six peripheral internal passages 891c, which are spaced from an outer surface of the ignitable heat source 820 and are smaller in diameter than that of the central internal passage 891a. It should be noted that in other implementations, there need not be a plurality of internal passages and/or the plurality of internal passages may take other forms and/or sizes. For example, in some implementations, there may be as few as two internal passages, and still other implementations may include as few as a single internal passage. Still other implementations may include no internal passages at all. Additional implementations may include multiple internal passages that may be of unequal diameter and/or shape and which may be unequally spaced and/or located within the heat source.

Some implementations may alternatively, or additionally, include one or more peripheral grooves that extend longitudinally from a first end of the heat source to an opposing second end, although in other implementations the grooves need not extend the full length of the heat source. In some implementations, such grooves may be substantially equal in width and depth and may be substantially equally distributed about a circumference of the heat source. In such implementations, there may be as few as two grooves, and still other implementations may include as few as a single groove. Still other implementations may include no grooves at all. Additional implementations may include multiple grooves that may be of unequal width and/or depth, and which may be unequally spaced around a circumference of the heat source. In still other implementations, the heat source may include flutes and/or slits extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end thereof. In some implementations, the heat source may comprise a foamed carbon monolith formed in a foam process of the type disclosed in U.S. Pat. No. 7,615,184 to Lobovsky, which is incorporated herein by reference in its entirety. As such, some implementations may provide advantages with regard to reduced time taken to ignite the heat source. In some other implementations, the heat source may be co-extruded with a layer of insulation (not shown), thereby reducing manufacturing time and expense. Other implementations of fuel elements include carbon fibers of the type described in U.S. Pat. No. 4,922,901 to Brooks et al. or other heat source implementations such as is disclosed in U.S. Pat. App. Pub. No. 2009/0044818 to Takeuchi et al., each of which is incorporated herein by reference in its entirety. Further examples of heat sources including debossed heat source systems, methods, and smoking articles that include such heat sources are disclosed in U.S. Pat. App. Pub. No. 2019/0254335 to Spicer et al., which is incorporated herein by reference in its entirety.

Generally, the heat source is positioned sufficiently near an aerosol delivery component (e.g., the substrate portion) having one or more aerosolizable components so that the aerosol formed/volatilized by the application of heat from the heat source to the aerosolizable components (as well as any flavorants, medicaments, and/or the like that are likewise provided for delivery to a user) is deliverable to the user by way of the mouthpiece. That is, when the heat source heats the substrate component, an aerosol is formed, released, or generated in a physical form suitable for inhalation by a consumer. It should be noted that the foregoing terms are meant to be interchangeable such that reference to release, releasing, releases, or released includes form or generate, forming or generating, forms or generates, and formed or generated. Specifically, an inhalable substance is released in the form of a vapor or aerosol or mixture thereof. Additionally, the selection of various smoking article elements is appreciated upon consideration of commercially available electronic smoking articles, such as those representative products listed in the background art section of the present disclosure.

FIG. 41 illustrates a longitudinal cross-section view of the cartridge 806 of FIG. 40. As shown in the figure, the substrate material 822 of the depicted implementation has opposed first and second ends, with the ignitable heat source 820 disposed adjacent the first end of the substrate material 822. Although dimensions and cross-section shapes of the various components of the cartridge may vary due to the needs of a particular application, in the depicted implementation the cartridge 806 may have an overall length in an inclusive range of approximately 10 mm to approximately 10 mm and a diameter in an inclusive range of approximately 2 mm to approximately 20 mm. In addition, in the depicted implementation the outer housing 898 may have a thickness in the inclusive range of approximately 0.05 mm to 0.5 mm. Furthermore, in the depicted implementation the substrate portion 822 may have a length in the inclusive range of approximately 1 mm to 30 mm and a diameter slightly less than that of the overall cartridge in order to accommodate the thickness of the housing 898, such as, for example, a diameter in an inclusive range of approximately 2.9 mm to approximately 9.9 mm. In the depicted implementation, the substrate material 822 comprises tobacco beads, which may have diameter sizes in range of approximately 0.5 mm to 2.0 mm, although in other implementations the size may differ. In other implementations, the substrate material may be a granulated tobacco material or cut filler tobacco. Although other implementations may differ, in the depicted implementation the outer housing 898 of the cartridge 806 is filled to about 80-90% capacity to allow for insertion of the fuel element 894.

In the depicted implementation, the substrate portion 822 comprises a substrate material 896 having a single segment, although in other implementations the substrate portion may include one or more additional substrate material segments. For example, in some implementations, the aerosol delivery device may further comprise a second substrate material segment (not shown) having opposed first and second ends. As described above, in various implementations, one or more of the substrate materials may include a tobacco or tobacco related material, with an aerosol precursor composition associated therewith. In other implementations, non-tobacco materials may be used, such as a cellulose pulp material. In other implementations, the non-tobacco substrate material may not be a plant-derived material. Other possible compositions and/or components for use in a substrate material (and/or substrate materials) are described above. Reference is also made to the discussion above regarding various possible shapes, aerosol precursor FIGS. 40 and 41, the outer housing 898 of the cartridge 806 of the depicted implementation is configured to circumscribe at least a portion of the substrate portion 822, including the substrate material 896. In the depicted implementation, the outer housing 898 is also configured to circumscribe a portion of the ignitable heat source 820. In some implementations, the outer housing may circumscribe the entire heat source. In the depicted implementation, the outer housing comprises a rigid material. For example, the outer housing 898 of the depicted implementation is constructed of an aluminum material; however, in other implementations the outer housing may be constructed of other materials, including other metal materials (such as, for example, stainless steel, aluminum, brass, copper, silver, gold, bronze, titanium, various alloys, etc.), or graphite materials, or ceramic materials, or plastic materials, or any combinations thereof. In some implementations, at least a portion of the heat source and/or at least a portion of the substrate material may be circumscribed by a paper foil laminate. In some implementations, the cartridge may comprise an enclosure comprising a laminate that contains a heat source and a beaded substrate material. Some examples of laminates and/or enclosures that may be applicable to the present disclosure can be found in U.S. Pat. App. Pub. No. 2020/0128880 to Gage et al., which is incorporated herein by reference in its entirety.

In the depicted implementation, the outer housing 898 is constructed as a tube structure that substantially encapsulates the substrate material 822; however, as noted above, in other implementations the outer housing may have other shapes. Although the shape of the outer housing may vary, in the depicted implementation the outer housing 898 comprises a tube structure having an open end and a closed end. The depicted implementation of the outer housing 898 also includes one or more end apertures 893 located on the closed end of the outer housing 898 that are configured to allow aerosolized vapor (herein alternatively referred to as a “vapor” or “aerosol”) to pass therethrough. The end apertures 893 of the depicted implementation are in the form of a pair of elongate rounded slots; however, in other implementations the end apertures may have any form that permits passage of the aerosol therethrough. As such, it will be appreciated that the end apertures 893 can comprise fewer or additional apertures and/or alternative shapes and sizes of apertures than those illustrated.

In various implementations, the present disclosure may also be directed to kits that provide a variety of components as described herein. For example, a kit may comprise a holder with one or more cartridges. In another implementation, a kit may comprise a plurality of holders. In further implementations, a kit may comprise a plurality of cartridges. In yet another implementation, a kit may comprise a plurality of holders and a plurality of cartridges. The inventive kits may further include a case (or other packaging, carrying, or storage component) that accommodates one or more of the further kit components. The case could be a reusable hard or soft container. Further, the case could be simply a box or other packaging structure. In some implementations, a brush or other cleanout accessory may be included in a kit. The cleanout accessory may be configured to be inserted in a cartridge receiving chamber of the holder, or, in other implementations, inserted in a separate aperture that enables a user to remove debris from the cartridge receiving chamber and/or ignitor contacts.

Many modifications and other embodiments of the disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed herein and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. An aerosol delivery device comprising: a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source, the main body further defining a first aerosol passageway that extends through at least a portion of the main body;a mouthpiece including a first end and a longitudinally opposed second end with a second aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the holder; andan access door movably coupled to the distal end of the main body and defining a third aerosol passageway, wherein, in an open configuration, the access door provides access to the receiving chamber for loading the removable cartridge therein and, in a closed configuration, fluidly couples the receiving chamber with the first aerosol passageway via the third aerosol passageway.

2. The aerosol delivery device of claim 1, wherein a sidewall of the holder defines an opening therethrough, the opening in fluid communication with the receiving chamber and disposed proximate the ignitable heat source when the removable cartridge is loaded within the receiving chamber

3. The aerosol delivery device of claim 2 further comprising: a power source disposed within the main body; anda pair of ignitor contacts in electrical communication with the power supply and disposed proximate the opening and configured to engage the ignitable heat source when the removable cartridge is loaded within the receiving chamber.

4. The aerosol delivery device of claim 3 further comprising an ignition switch in electrical communication with the power source and the ignitor contacts and configured to provide power to the contacts when actuated.

5. The aerosol delivery device of claim 1, wherein the access door is coupled to the main body via a detent hinge configured maintain the access door in at least one of the open configuration or the closed configuration.

6. The aerosol delivery device of claim 1, wherein the access door sealingly engages the distal end of the main body in the closed configuration.

7. The aerosol delivery device of claim 1, wherein the third aerosol passageway is configured to redirect a vapor path extending through the main body about 180°.

8. The aerosol delivery device of claim 1 further comprising an actuator assembly coupled to the holder and configured to eject the removable cartridge therefrom.

9. The aerosol delivery device of claim 8, wherein the actuator assembly comprises: a slider body slidably disposed within the main body of the holder and configured to slide along a length of the main body in a first direction and a second direction;a slider button disposed on a surface of the slider body and configured to be accessible to a user; anda stem extending beyond a distal end of the slider body and configured to engage with the ignitable heat source of the removable cartridge to drive the cartridge at least partially out of the receiving cavity.

10. The aerosol delivery device of claim 2, wherein the opening is configured to provide air intake therethrough for mixing with an aerosol generated by the removable cartridge and deliverable to a user via the mouthpiece.

11. An aerosol delivery device having different consumable loading and ejecting paths comprising: a holder comprising an upper body portion and a lower body portion, each defining a proximal end and a distal end, wherein:the lower body portion further defines a receiving chamber disposed in the proximal end thereof and configured to receive a removable cartridge therein, andthe upper body portion comprises an actuator assembly slidably disposed within the upper body portion and configured to eject the removable cartridge from the lower body portion via the distal end thereof and defining a first aerosol passageway, wherein the upper body portion and the lower body portion are coupled together and configured to be rotatable relative to one another between an open configuration exposing the receiving chamber for loading the removable cartridge and closed configuration where the cartridge may be ejected from the distal end of the lower body portion.

12. The aerosol delivery device of claim 11, wherein the actuator assembly comprises: a tubular body defining a portion of the first aerosol passageway and configured to slide along a portion of the upper body portion in a first direction and a second direction;a first protrusion extending from an outer surface of the tubular body and configured to extend through an opening in a wall of the upper body portion to provide for moving the tubular body in the first and second directions; anda second protrusion extending from a distal end of the tubular body and configured to engage the removable cartridge so as to advance the removable cartridge through the distal end of the lower body portion when the tubular body is moved in the first or second direction.

13. The aerosol delivery device of claim 11 further comprising a pair of ignitor contacts coupled to the lower body portion and disposed proximate the distal end thereof, wherein the ignitor contacts are configured to engage with an ignitable heat source portion of the removable cartridge when the removable cartridge is secured within the receiving chamber.

14. The aerosol delivery device of claim 11 further comprising a locking mechanism disposed on at least one of the lower body portion or the upper body portion and configured to maintain the device in the closed configuration.

15. An aerosol delivery device having different consumable loading and ejecting paths comprising: a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge, the main body further defining a first aerosol passageway that extends through at least a portion of the main body, wherein a sidewall of the holder defines an opening therethrough and in communication with the receiving chamber;an access door sealingly coupled to the main body and disposed proximate the opening, wherein, in an open configuration, the access door is positioned so as to expose the opening to provide access to the receiving chamber for loading the removable cartridge therein and, in a closed configuration, the access door is positioned to cover the opening so as to secure the cartridge in fluid communication with first aerosol passageway; andan actuator assembly coupled to the main body and configured to eject the removable cartridge through the distal end thereof.

16. The aerosol delivery device of claim 15 further comprising: a power source disposed within the main body; anda pair of ignitor contacts in electrical communication with the power supply and disposed proximate the distal end of the main body and configured to engage an ignitable heat source portion of the removable cartridge when the removable cartridge is secured within the receiving chamber.

17. The aerosol delivery device of claim 15, wherein the access door is slidably coupled to the main body and configured to be slid distally into the open configuration.

18. The aerosol delivery device of claim 17 further comprising a latching mechanism configured to secure the access door in the closed configuration.

19. An aerosol delivery device comprising: a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source therein and a receptacle that extends along at least a portion of the main body; anda mouthpiece movably coupled to the main body and including a first end and a longitudinally opposed second end with a first aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the holder; andwherein the mouthpiece is configured to translate between an open configuration where the receiving chamber is exposed for loading of the removable cartridge and a closed configuration where the first aerosol passageway is generally aligned with the receiving chamber.

20. The aerosol delivery device of claim 19 further comprising a translating mechanism movably coupled to the main body and at least partially disposed within the receptacle, wherein the translating mechanism is configured to couple the mouthpiece to the holder and bias the mouthpiece into the closed configuration.

21. The aerosol delivery device of claim 20, wherein the main body receptacle is configured to at least partially receive the translating mechanism and the mouthpiece in the open configuration.

22. The aerosol delivery device of claim 21, wherein the mouthpiece is translated into the receptacle upon application of a force to the translating mechanism.

23. The aerosol delivery device of claim 20, wherein a distal end of the translating mechanism or the second end of the mouthpiece is configured to sealingly engage the receiving chamber in the closed configuration.

24. The aerosol delivery device of claim 19, wherein the mouthpiece is slidably disposed within the main body and configured to eject the removable cartridge from the distal end of the main body.

25. The aerosol delivery device of claim 20, wherein the mouthpiece comprises a first enlarged portion disposed at the first end of the mouthpiece and a second elongate portion extending from the enlarged portion to the second end of the mouthpiece.

26. The aerosol delivery device of claim 25, wherein the translating mechanism comprises: a channel extending therethrough and configured to allow the elongate portion of the mouthpiece to slidably move in a first direction and a second direction therein; anda stop disposed within the channel configured to engage the enlarged portion of the mouthpiece to limit travel of the mouthpiece in the first direction.

27. The aerosol delivery device of claim 26, wherein the stop is configured to prevent the mouthpiece from exiting the distal end of the main body.

28. The aerosol delivery device of claim 26 further comprising a biasing mechanism disposed within the holder or the translating mechanism and configured to bias the mouthpiece in the second direction.

29. An aerosol delivery device comprising: a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source therein; anda mouthpiece movably coupled to the main body and including a first end and a longitudinally opposed second end with a first aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the holder so as to provide fluid communication between the receiving chamber and the first aerosol passageway; anda biasing mechanism disposed within the main body and operatively coupled to the mouthpiece, wherein the biasing mechanism is configured to maintain the mouthpiece in a neutral orientation and the mouthpiece is actuatable to eject the removable cartridge from the receiving chamber.

30. The aerosol delivery device of claim 29, wherein the mouthpiece is actuated via application of a force to the first end of the mouthpiece that is greater than a resistance of the biasing mechanism.

31. The aerosol delivery device of claim 29, wherein the second end of the mouthpiece is configured to sealingly engage with the receiving chamber or the removable cartridge.

32. The aerosol delivery device of claim 29 further comprising: a receptacle defined by the holder and extending along at least a portion of the main body; anda translating mechanism movably coupled to the main body and at least partially disposed within the receptacle, wherein the translating mechanism is configured to couple the mouthpiece to the holder and move the mouthpiece between an open configuration where the receiving chamber is exposed for loading of the removable cartridge and a closed configuration where the first aerosol passageway is generally aligned with the receiving chamber.

33. An aerosol delivery device comprising: a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source, the main body further defining a first aerosol passageway that extends through at least a portion of the main body;a mouthpiece including a first end and a longitudinally opposed second end with a second aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the holder; andan access door pivotably coupled to the distal end of the main body and defining an opening therein, wherein, in an open configuration, the access door provides access to the receiving chamber for loading the removable cartridge therein and, in a closed configuration, secures the removable cartridge in the receiving chamber for ignition thereof.

34. The aerosol delivery device of claim 33 further comprising: a power source disposed within the main body; anda pair of ignitor contacts disposed within the access door and in electrical communication with the power source when the access door is in the closed configuration.

35. The aerosol delivery device of claim 34, wherein the ignitor contacts are partially disposed within the opening in the access door and configured to engage the ignitable heat source when a cartridge is disposed within the receiving chamber and the access door is in the closed configuration.

36. The aerosol delivery device of claim 34 further comprising an ignition switch in electrical communication with the power source and the ignitor contacts and configured to provide power to the contacts when actuated.

37. The aerosol delivery device of claim 34, wherein the distal end of the main body and the access door each comprise a mating half of an electrical coupling.

38. The aerosol delivery device of 37, wherein the distal end of the main body comprises at least one electrical contact in electrical communication with the power source and the access door comprises at least one mating electrical contact in electrical communication with the ignitor contacts, wherein the electrical contacts complete an electrical circuit when the access door is in the closed configuration.

39. The aerosol delivery device of 38, wherein the electrical circuit is disrupted when the access door is in the open configuration.

40. The aerosol delivery device of claim 33, wherein the device further comprises a biasing mechanism disposed within the main body and configured to bias the access door into the closed configuration.

41. The aerosol delivery device of claim 33, wherein the receiving chamber comprises a biasing mechanism disposed therein, the biasing member configured to maintain the removable cartridge in contact with the ignitor contacts in the closed configuration.

42. An aerosol delivery device comprising: a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source; anda removable mouthpiece comprising: an elongate body portion defined by a first end and a longitudinally opposed second end and defining an aerosol passageway extending therethrough;a first retention mechanism disposed about an exterior surface of the elongate body portion, the first retention mechanism configured to removably secure the second end of the mouthpiece within the holder; anda second retention mechanism disposed within a receptacle defined by the second end of the elongate body member, the second retention mechanism configured to removably secure a portion of the cartridge therein, wherein the first end of the mouthpiece is configured to engage with a user's mouth.

43. The aerosol delivery device of claim 42 further comprising an inner housing disposed within the main body of the holder and defining a passageway therethrough configured to receive a portion of the mouthpiece therein.

44. The aerosol delivery device of claim 43, wherein the first retention mechanism is configured to sealingly engage with the passageway in the inner housing.

45. The aerosol delivery device of claim 44, wherein the first retention mechanism includes an elastomeric seal disposed about an exterior surface thereof and configured to frictionally engage with the inner housing passageway.

46. The aerosol delivery device of claim 42, wherein the second retention mechanism includes an elastomeric seal disposed about an interior surface thereof and configured to frictionally engage with the cartridge.

47. An aerosol delivery device comprising: a holder comprising a main body defining a proximal end and a distal end, the main body further defining a receiving chamber configured to receive a removable cartridge comprising an ignitable heat source; anda removable mouthpiece configured to engage the proximal end of the holder and comprising: a first portion comprising an elongate body defined by a first end and a longitudinally opposed second end and defining a passageway extending therethrough;a second portion defined by a first end and a longitudinally opposed second end and defining a first aerosol passageway therethrough, wherein the first end of the second portion is configured to engage with a user's mouth and the second end is partially disposed within the passageway of the first portion of the mouthpiece proximate the first end of the first portion;a slider body defined by a first end and a longitudinally opposed second end and defining a second aerosol passageway therethrough, wherein the slider body is slidably disposed within the first portion of the mouthpiece and the first end of the slider body is coupled to the second end of the second portion of the mouthpiece and the second end of the slider body is configured to engage the removable cartridge;an inner tubular body defined by a first end and a longitudinally opposed second end and defining a receptacle comprising a first biasing mechanism disposed therein, the receptacle configured to at least partially receive the slider body, the slider body slidably coupled to the inner tubular body, wherein the second end of the inner tubular body is configured to engage the first portion of the mouthpiece proximate the second end of the first portion and the biasing mechanism is configured to maintain the slider body in a loading configuration; andan outlet guide coupled to the second end of the first portion of the mouthpiece and partially received within the second end of the inner tubular body, wherein the outlet guide defines a cavity configured to sealingly engage and removably secure the removable cartridge therein.

48. The aerosol delivery device of claim 47, wherein the holder further comprises: a pair of ignitor contacts disposed within the receiving chamber proximate the distal end of the holder; anda second biasing mechanism disposed within the main body and configured to engage a distal end of the mouthpiece, wherein the mouthpiece is slidably disposed within the main body and the second biasing mechanism is configured to position an ignitable heat source portion of the cartridge away from the ignitor contacts.

49. The aerosol delivery device of claim 48, wherein the holder further comprises: an inner housing disposed within the main body of the holder and defining one or more receptacles therein;an outer tubular body disposed within a first one of the receptacles and defining an interior cavity configured to slidably receive the mouthpiece therein;a first end cap coupled to proximal end of the holder and defining a first opening in communication with the interior cavity of the outer tubular body, the first end cap configured to secure at least one of the inner housing or the outer tubular body within the holder; anda second end cap coupled to the distal end of the holder and defining a second opening in communication with the interior cavity of the outer tubular body, the second end cap configured to secure at least one of the inner housing or the outer tubular body within the holder.

50. The aerosol delivery device of claim 49, wherein the second biasing mechanism comprises: a return spring; anda collar slidably disposed within the outer tubular body, a distal end of the collar configured to engage the return spring.

51. The aerosol delivery device of claim 50, wherein the first biasing mechanism comprises an ejection spring and the ejection spring has a greater spring force than the return spring.

52. The aerosol delivery device of claim 47, wherein the second end cap further comprises a standoff extending into the inner housing and partially defining the receiving chamber.

53. The aerosol delivery device of claim 52, wherein the standoff comprises a pair of opposing slots configured to secure the ignitor contacts therein.

54. The aerosol delivery device of claim 47, wherein the holder comprises a retention mechanism configured to movably couple the mouthpiece to the holder.

55. The aerosol delivery device of claim 47 further comprising: a power source disposed within the inner housing;a printed circuit board disposed within the inner housing and in electrical communication with the ignitor contacts; anda switch in electrical communication with the power source and the printed circuit board and configured to electrically couple the power source to the ignitor contacts.

56. The aerosol delivery device of claim 1 further comprising the removable cartridge, wherein the cartridge includes a substrate material having an aerosol precursor composition configured to form an aerosol upon application of heat thereto.

57. The aerosol delivery device of claim 11 further comprising a mouthpiece including a first end and a longitudinally opposed second end with a second aerosol passageway extending longitudinally therebetween, wherein the first end is configured to engage with a user's mouth and the second end is configured to engage the proximal end of the holder.

58. The aerosol delivery device of claim 1, wherein the mouthpiece is removable.