Abstract: A smoking system is provided in which a replaceable cigarette containing tobacco flavor material is electrically heated by a set of electrical heater elements contained within a lighter to evolve tobacco flavors or other components in vapor or aerosol form for delivery to a smoker. The cigarette and lighter are adapted to provide air flow patterns through the smoking system such that air flows transversely into the cigarette. Such patterns improve aerosol and flavor delivery to the smoker and reduce the condensation of residual heater-region vapor/aerosol in the smoking system.

Abstract: A bladed tubular array for use as a heating element in an electrical smoking article, and a tobacco flavor element for such an article based thereon, are provided. The integral carbon heater preferably provides eight thermally and electrically discrete heating zones to provide an optimized heating zone when each blade is individually powered. Each blade has a desired resistance, to provide temperature preferably in the range of from about 300.degree. C. to about 900.degree. C., or higher. The relatively brittle carbon composite conductive blades are supported by a reinforcing tube of spiral-wound paperboard. A common ring of the same conductive material serves as a common electrical terminal for the blades, while the free end of each blade serves as the other electrical terminal of that blade.

Abstract: A smoking article is provided in which a flavor-generating medium is heated electrically to release an aerosol for inhalation by a consumer. The smoking article includes a heater having resistive heating elements printed on a flexible substrate. The heater can be manufactured by circuit board mass production techniques, and can be formed to fit inside an article of the same shape and size as a conventional cigarette. Alternatively, the heater comprises an array of heating elements onto which charges of flavor-generating medium are deposited. The heating elements are connected in a manner which allows the temperature increase in the heater to be concentrated in individually selected heating elements, and requires a minimal number of electrical conductors.

Abstract: This invention relates to a heat source comprising metal carbide and a method for preparing the same using a reducing/carbidizing atmosphere. The metal carbide heat sources of this invention have ignition temperatures that are substantially lower than conventional carbon particles normally used in carbonaceous heat sources, while at the same time provide sufficient heat to release a flavored aerosol from a flavor bed for inhalation by the smoker. Upon combustion, the heat sources produce substantially no carbon monoxide.

Abstract: This invention relates to improved methods for making a composite heat source comprising carbon and metal species. The composite heat source made by the methods of this invention have ignition temperatures that are substantially lower than carbonaceous heat sources, while at the same time provide sufficient heat to release a flavored aerosol from a flavor bed for inhalation by the smoker. Upon combustion, the heat source produces substantially no carbon monoxide. The metal species may be prepared by mixing a metal oxide, metal and a carbon source, pre-forming the metal oxide/metal/carbon source mixture into a shape and converting the mixture to metal species in situ, without substantially altering the original shape of the mixture.

Abstract: An improved carbonaceous heat source suitable for use in a smoking article is provided. The heat source is formed by mixing a carbon component, a catalytic precursor and a binder, forming the mixture into a shape, and supplying heat to the mixture. Upon combustion of the heat source, the catalytic precursor forms a catalyst that converts carbon monoxide produced during combustion of the heat source into a benign substance.

Abstract: A heating element for use within a smoking device which is intended to be held in the lips of a consumer, and which, without burning, heats a flavor-generating medium within the device to produce an aerosol, vapor, or flavor, which the consumer may inhale. More particularly, an electrically-powered heating element having a plurality of discrete resistive heating segments, only one of which is active at any given time. In a preferred embodiment, the heating element is contained within the device so that the individual heating segments of the element are adjacent to a flavor-generating medium. As each segment of the heating element is provided with power, the flavor-generating medium adjacent to that segment is heated, but is not burned. This heating causes the flavor-generating medium to produce a flavor, aerosol, or vapor, which the consumer of the device may inhale.

Abstract: A chemical heat source comprising metal nitride, metal oxide and carbon, particularly useful in smoking articles, and methods of making the heat source are provided. The metal nitride of the heat source has an ignition temperature substantially lower than conventional carbonaceous heat sources, while at the same time provides sufficient heat to release a flavored aerosol from a flavor bed for inhalation by the smoker. Upon combustion the heat source produces virtually no carbon monoxide. The metal nitride is prepared by pre-forming the starting materials into a desired shape, and converting them to metal nitride in situ, without substantially altering the shape of the starting materials.

Abstract: This invention relates to a heat source comprising a mixture of metal carbide, metal nitride and metal which undergo a staged ignition process, particularly useful in smoking articles. The metal carbide/metal nitride/metal mixtures making up the heat source have ignition temperatures that are substantially lower than conventional carbonaceous heat sources, while at the same time provide sufficient heat to release a flavored aerosol from a flavor bed for inhalation by the smoker. Upon combustion the heat source produces substantially no carbon monoxide or nitrogen oxides.

Abstract: A heating element for use within a smoking device which is intended to be held in the lips of a consumer, and which without burning, heats a flavor-generating medium within the device to produce an aerosol, vapor, or flavor, which the consumer may inhale. More particularly, an electrically-powered heating element having a plurality of discrete resistive heating segments, only one of which is active at any given time. In a preferred embodiment, the heating element is contained within the device so that the individual heating segments of the element are adjacent to a flavor-generating medium. As each segment of the heating element is provided with power, the flavor-generating medium adjacent to that segment is heated, but is not burned. This heating causes the flavor-generating medium to produce a flavor, aerosol, or vapor, which the consumer of the device may inhale.