Abstract: A method and apparatus for detecting, locating, isolating and controlling variations in the manufacturing process by transient thermography. A heat source (200) imparts heat to a surface which is radiated in the infrared region. Infrared sensors (204, 206, 208, 210) are coupled to a processor which tracks the physical characteristics of the sample, and provides feedback to a central process controller to make adjustments to the manufacturing process. The sample can be a continuous product such as a green powder metal sheet or tobacco product.

Abstract: The invention relates generally to aluminum containing iron-base alloys useful as electrical resistance heating elements. The aluminum containing iron-base alloys have improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The alloy has an entirely ferritic microstructure which is free of austenite and includes, in weight %, over 4% Al, ≦1% Cr and either ≧0.05% Zr or Zro2 stringers extending perpendicular to an exposed surface of the heating element or ≧0.1% oxide dispersoid particles. The alloy can contain 14-32% Al, ≦2% Ti, ≦2% Mo, ≦1% Zr, ≦1% C, ≦0.1% B. ≦30% oxide dispersoid and/or electrically insulating or electrically conductive covalent ceramic particles, ≦1% rare earth metal, ≦1% oxygen, ≦3% Cu, balance Fe.

Abstract: The invention relates generally to aluminum containing iron-base alloys useful as electrical resistance heating elements. The aluminum containing iron-base alloys have improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The alloy has an entirely ferritic microstructure which is free of austenite and includes, in weight %, over 4% Al, ≦1% Cr and either ≧0.05% Zr or ZrO2 stringers extending perpendicular to an exposed surface of the heating element or ≧0.1% oxide dispersoid particles. The alloy can contain 14-32% Al, ≦2% Ti, ≦2% Mo, ≦1% Zr, ≦1% C, ≦0.1% B, ≦30% oxide dispersoid and/or electrically insulating or electrically conductive covalent ceramic particles, ≦1% rare earth metal, ≦1% oxygen, ≦3% Cu, balance Fe.

Abstract: A novel controller in an electrical smoking system and method, wherein the method includes the steps of: establishing a preferred thermal pathway to be executed with each heater activation responsively to a puff on an electrically heated cigarette; configuring a power cycle in accordance with the desired thermal pathway; dividing the power cycle into at least first and second phases each having a respective, predetermined time period and total energy input for each phase; and adjusting a respective duty cycle (or other power-adjusting factor) in each phase of the power cycle responsively to a voltage reading of the power source such that the established, respective total energy input of each phase is achieved during the time period of each power cycle.

Abstract: The invention relates generally to aluminum containing iron-base alloys useful as electrical resistance heating elements. The aluminum containing iron-base alloys have improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The alloy has an entirely ferritic microstructure which is free of austenite and includes, in weight %, over 4% Al, .ltoreq.1% Cr and either .gtoreq.0.05% Zr or ZrO.sub.2 stringers extending perpendicular to an exposed surface of the heating element or .gtoreq.0.1% oxide dispersoid particles. The alloy can contain 14-32% Al, .ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Zr, .ltoreq.1% C, .ltoreq.0.1% B, .ltoreq.30% oxide dispersoid and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1% rare earth metal, .ltoreq.1% oxygen, .ltoreq.3% Cu, balance Fe.

Abstract: A novel electrical smoking system and method of establishing resistance to draw upon a cigarette while smoking a cigarette in an electrical smoking system comprising the step of operatively interposing a frit between a source of ambient air and the cigarette.

Abstract: Methods and apparatuses for cleaning an electrical lighter are provided. A sleeve, e.g., ceramic or metal, surrounds the heater fixture, and a resistive heating element is in thermal proximity with the sleeve. The resistive heating element is either a dedicated element or the cigarette heating elements. The sleeve serves as a aerosol barrier and condensate accumulator to protect other components. Periodically, e.g., substantially contemporaneously with a battery recharge, the heating element is activated to thermally liberate condensates deposited on the sleeve during smoking and also heats, and thereby cleans, other components. Also, a cleaning element is optionally inserted into the cigarette receptacle of the electrical lighter or placed at the exit thereof to absorb, attract and/or catalytically break down the thermally liberated condensates. The sleeve also directs a desired flow path for drawn air within an electrical lighter toward the cigarette.

Abstract: A smoking article is provided in which a replaceable tobacco flavor unit containing tobacco flavor material is electrically heated by a set of permanent reusable heaters to evolve flavors or other components in vapor or aerosol form for delivery to a smoker. Each heater heats only a portion of the available tobacco flavor material so that a plurality of individual puffs of tobacco flavor substance can be delivered sequentially to the smoker. The replaceable tobacco flavor unit can also include a filter to reduce the effect of residual aerosol which settles or condenses on the permanent portions of the article and which can result in undesirable flavor generation when reheated. A method and apparatus for manufacturing the replaceable tobacco flavor unit is also provided.

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: An ejection system is provided which has a mechanism such as a plunger which is positioned to eject at least a portion of a cigarette from the lighter cavity upon actuation by a smoker. The plunger is also positionable to occlude the lighter opening to protect the lighter cavity from dust, moisture, etc. The plunger is shaped, located and arranged to apply a force on the cigarette end inserted into the lighter. Further, an icon based indicator informs the smoker of the status of a cigarette inserted into the lighter.

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 novel cigarette of an electrical cigarette system and method of making same, the cigarette comprising a tubular tobacco web and a plug disposed within said tubular tobacco web which provides a structural connection that remains intact after a smoking of the cigarette. The disclosure includes a double-belled plug extending between a free end and a tipped end of a tobacco rod, or in the alternative, a column of tobacco with higher and lower density segments. The disclosure includes a method comprising the steps of producing a continuous plug, passing same through a die, overwrapping the rod with tobacco mat and overwrap, and severing the rod.

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 cylindrical tube is provided of a mechanically strong and flexible electrical conductor such as a metal and has a plurality of separated regions. An electrically insulating layer such as a ceramic is applied on the outer surface except for one exposed portion. Electrically resistive heaters are then applied to the insulated regions and are electrically connected at one end to the underlying electrical conducting region. The electrical conductor is connected to the negative terminal of a power source. The other end of all the heaters are adapted to be connected to the positive terminal of the source. Accordingly, an electrically resistive heating circuit is formed wherein the tube serves as a common for all of the heating elements. The tubular heater can comprise an exposed end hub with a plurality of blades extending therefrom. Each blade can have an individual heater deposited thereon. Alternatively, every other blade can have a heater deposited thereon.

Abstract: A lighter is provided having a tobacco flavor heating system which includes a rotatable tobacco containing disc or spiral. This disc or spiral is registered in thermal proximity to a heating element and heated to generate tobacco flavors in response to a sensor. The disc and spiral are sized to provide a convenient number of puffs before disposal. Housings are provided for the disc and spiral to store, register and dispose the tobacco product efficiently. An induction heating system can be employed.

Abstract: The invention relates generally to aluminum containing iron-base alloys useful as electrical resistance heating elements. The aluminum containing iron-base alloys have improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The alloy has an entirely ferritic microstructure which is free of austenite and includes, in weight %, over 4% Al, .ltoreq.1% Cr and either .gtoreq.0.05% Zr or ZrO.sub.2 stringers extending perpendicular to an exposed surface of the heating element or .gtoreq.0.1% oxide dispersoid particles. The alloy can contain 14-32% Al, .ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Zr, .ltoreq.1% C, .ltoreq.0.1% B, .ltoreq.30% oxide dispersoid and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1% rare earth metal, .ltoreq.1% oxygen, .ltoreq.3% Cu, balance Fe.

Abstract: A smoking article is provided in which a replaceable tobacco flavor unit containing tobacco flavor material is electrically heated by a set of permanent reusable heaters to evolve flavors or other components in vapor or aerosol form for delivery to a smoker. Each heater heats only a portion of the available tobacco flavor material so that a plurality of individual puffs of tobacco flavor substance can be delivered sequentially to the smoker. The replaceable tobacco flavor unit can also include a filter to reduce the effect of residual aerosol which settles or condenses on the permanent portions of the article and which can result in off-tastes when reheated. A method and apparatus for manufacturing the replaceable tobacco flavor unit is also provided.

Abstract: An induction heating source is provided for use with an electrical smoking article. The induction heating source provides an alternating electromagnetic field which inductively heats a susceptor in thermal proximity with tobacco flavor medium to generate aerosols. A plurality of induction heaters are employed and/or the tobacco flavor medium is translated with respect to the induction heater or susceptor. The tobacco flavor medium can form an intimate structure with the susceptor and can take the form of a cylindrical cigarette or a web.

Abstract: The invention relates generally to aluminum containing iron-base alloys useful as electrical resistance heating elements. The aluminum containing iron-base alloys have a disordered body centered cubic structure and improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The alloy has an entirely ferritic microstructure which is free of austenite and includes, in weight %, 4 to 9.5% Al, 0.2-2.0% Ti, 0.5-2% Mo, 0.1 to 0.8% Zr, 0.01-0.5% C, balance Fe.

Abstract: A provided heater comprises a supporting hub and a plurality of electrically resistive heater blades defining a receptacle to receive an inserted cigarette. Each blade comprises a first heater blade leg having a first end and a second end and extending at the first end from the supporting hub, a second heater blade leg having a first end and a second end, and a connecting section connecting the second end of the first leg and the first end of the second leg. The second end of the second leg extends toward the supporting hub and is electrically insulated therefrom. A resistive heating circuit is formed to heat the electrically resistive heater blade which in turn heats the inserted cigarette. The first and second legs are separated by a gap to permit entrainment of flavor substances into the heated cigarette upon drawing by a smoker.