Abstract: A heater having a generally cylindrical or tubular configuration comprised of a selected plurality of thermally conductive heater blades and adjacent heat sink and aerosol barrier blades interposed between the heater blades to form an interdigitated structure. A respective gap is defined between a heater blade and an adjacent heat sink blade to prevent heat loss during an electrical pulse which heats the heater blade. During the subsequent cooling period and puff interval, the adjacent heat sink blades prevent heat from propagating to other parts of the aerosol generating tube, i.e., the cigarette. In addition to the thermal function, the barrier blades also block the escape of moisture generated by the aerosol generating medium, thereby limiting the propagation of condensation. The respective gaps between the interdigitated blades are defined to be wide enough to prevent heat losses during pulsing from a heater blade to adjacent blades yet small enough to prevent escape of significant amounts of vapor.

Abstract: A heater having a multiple-layer ceramic substrate and a method for fabricating the heater are provided. The heater consists-of a plurality of ceramic layers which are laminated to form a single ceramic substrate. A plurality of resistive heating elements are deposited onto the multiple-layer ceramic substrate, which are connectable to a power source via conductive elements which extend through the substrate to the resistive heating elements. The heater may also include a terminal that allows for convenient electrical and mechanical interfacing to a smoking article.

Abstract: A plurality of resistive heating elements and conductive elements are screenprinted onto a ceramic substrate to form a heater having multiple resistive heating elements. Slots formed between adjacent resistive heating elements members provide air gaps to thermally insulate each heating element from neighboring elements. Gold-plated leads provide low contact resistance for receiving power from a battery for energizing each of the resistive heating elements.

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 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: Methods and apparatus for releasing flavor components from a flavor-generating medium using an electric heating element are provided. A non-combustion flavor-generating article uses electrical energy to power a heating element which heats tobacco or other flavorants. The flavor-generating medium is formed into a packed bed. Energy delivered to the heating element is regulated to maintain the flavor-generating medium at a relatively constant operating temperature to ensure a relatively constant release of flavor.