Abstract: The present disclosure relates to systems, apparatuses, and methods for assembling cartridges for aerosol delivery devices. The cartridges may be assembled by transporting carriages between various substations at which parts are added to a base. In another assembly method, the base may be moved between a plurality of robots which direct the base downwardly into contact with components to couple the components therewith. An inspection system may inspect the cartridges at various stages of completion.

Abstract: The present disclosure relates to an aerosol delivery device that includes a reservoir housing that defines a mouthpiece channel. The aerosol delivery device includes a sealing member configured to be received within the reservoir housing to define a reservoir chamber configured to retain an aerosol precursor composition therein. The aerosol delivery device also includes a substrate member that is configured to be received within the reservoir housing and to be directly engaged with a vaporizing assembly for forming an aerosol. The reservoir housing, sealing member, substrate member, and/or vaporizing assembly can be used for forming aerosols with precise and reproducible compositions.

Abstract: The present disclosure relates to systems, apparatuses, and methods for assembling cartridges for aerosol delivery devices. The cartridges may be assembled by transporting carriages between various substations at which parts are added to a base. In another assembly method, the base may be moved between a plurality of robots which direct the base downwardly into contact with components to couple the components therewith. An inspection system may inspect the cartridges at various stages of completion.

Abstract: The present disclosure relates to a cartridge for an aerosol delivery device such as a smoking article. The cartridge may include a base, a reservoir substrate, and an atomizer. The reservoir substrate may define a cavity therethrough. The atomizer may comprise a liquid transport element and a heating element extending at least partially about the liquid transport element. The atomizer may extend through the cavity through the reservoir substrate such that the heating element is positioned proximate an end of the reservoir substrate. Ends of the liquid transport element may extend to an opposing end of the reservoir substrate. A related method for assembling a cartridge for a smoking article is also provided.

Abstract: The present disclosure relates to a cartridge for an aerosol delivery device such as a smoking article. The cartridge may include a base, a reservoir substrate, and an atomizer. The reservoir substrate may define a cavity therethrough. The atomizer may comprise a liquid transport element and a heating element extending at least partially about the liquid transport element. The atomizer may extend through the cavity through the reservoir substrate such that the heating element is positioned proximate an end of the reservoir substrate. Ends of the liquid transport element may extend to an opposing end of the reservoir substrate. A related method for assembling a cartridge for a smoking article is also provided.

Abstract: The present disclosure relates to an aerosol delivery device. The aerosol delivery device may include a control body and a cartridge. The cartridge may include a base, a flow director, an outer body, a reservoir substrate, an outer body, and a mouthpiece. Heating elements may be molded into the flow director. The flow director may be welded to the base and the outer body, or the base and the flow director may include deformable ribs that engage the outer body. The flow director and the outer body may cooperatively define a reservoir compartment in which the reservoir substrate and the atomizer are received. The flow director and the base may define an electronics compartment in which an electronic control component is received. A related assembly method is also provided.

Abstract: A cigarette includes lighting and mouth ends. It may include a smokable segment disposed at the lighting end. It also includes a mouth-end segment; an aerosol-generation system disposed between the lighting and mouth ends, which includes (i) a heat-generation segment adjacent the smokable segment, including a heat source and an insulation layer and (ii) an aerosol-generating segment including a substrate, which may include tobacco pellets and aerosol-forming material disposed in a substrate cavity between the heat generation segment and the mouth end; a piece of outer wrapping material that provides an overwrap around at least a portion of the aerosol-generating segment, the heat-generation segment, and at least a portion of the smokable segment and includes a foil strip laminated thereon; those segments being connected together by the overwrap to provide a cigarette rod; that is connected to the mouth-end segment using tipping material.

Abstract: The present disclosure relates to systems, apparatuses, and methods for assembling cartridges for aerosol delivery devices. The cartridges may be assembled by transporting carriages between various substations at which parts are added to a base. In another assembly method, the base may be moved between a plurality of robots which direct the base downwardly into contact with components to couple the components therewith. An inspection system may inspect the cartridges at various stages of completion.

Abstract: The present disclosure relates to an aerosol delivery device. The aerosol delivery device may include a first outer body, a second outer body, and a coupler received therebetween. A securing mechanism may couple the outer bodies together to retain the aerosol delivery device in an assembled configuration. For example, the coupler may be welded to the first outer body and the second outer body. Related assembly methods are also provided.

Abstract: The present disclosure relates to an aerosol delivery device. The aerosol delivery device may include a first outer body, a second outer body, and a coupler received therebetween. A securing mechanism may couple the outer bodies together to retain the aerosol delivery device in an assembled configuration. Related assembly methods are also provided.

Abstract: The present disclosure provides components useful in heating, particularly heating of an aerosol precursor solution so as to vaporize the solution and form an aerosol. The disclosure particularly provides an electrically conductive, porous carbon heater. The heater may be combined with an aerosol precursor transport element that also is formed of carbon. The heater and transport element may form an atomizer that can be useful in an electronic smoking article, such as in a cartridge that is adapted for attachment to a control body. In some embodiments, the disclosure provides a cartridge of an electronic smoking article, the cartridge being formed substantially completely of carbon.

Abstract: The present disclosure relates to reservoirs for storing products in electronic smoking articles. The reservoir is manufactured from cellulose acetate fiber, thermoplastic fiber, non-thermoplastic fiber, or a combination thereof. The reservoir is substantially tubular in shape and is adapted to accommodate internal components of the smoking article thereby increasing reservoir capacity. The internal components particularly can comprise an atomizer, which may include a braided wick.

Abstract: Smoking articles, and methods for forming such smoking articles, such as an electronic smoking article, are provided. An exemplary smoking article comprises a control body portion having a control body engagement end, and having a first control component therein. A cartridge body portion includes a cartridge body engagement end configured to removably engage the control body engagement end of the control body portion. The cartridge body portion further includes a consumable arrangement comprising at least an aerosol precursor composition and at least one heating element operably engaged therewith, and a second control component. At least the consumable arrangement is configured to be in communication with the first control component upon engagement between the cartridge body and control body portions.

Abstract: The present invention provides a conductive substrate useful for Joule heating, such as in an electronic smoking article. Particularly, the invention provides a resistive heating element formed of a conductive substrate. The conductive substrate comprises an electrically conductive material and a carbonaceous additive, such as a binder material. The conductive substrate is carbonized in that it is subjected to calcining conditions to effectively reduce the carbonaceous additive to its carbon skeleton. It has been found that such carbonized substrate has surprisingly improved resistance properties in relation a substrate of the same formulation that is not carbonized. The carbonized substrate can include an aerosol precursor material. The formed resistive heating element can be included in an electronic smoking article to simultaneously provide resistive heating and aerosol formation with a single, unitary component.

Abstract: The invention provides a cigarette with a filter element comprising at least one longitudinally extending section of filter material. The section of filter material comprises a smoke-altering material therein that is useful for removing a quantity of vapor phase chemicals from the mainstream smoke. The section of filter material further comprises one or more tubes inserted into and extending through section of filter material. The one or more tubes each define a channel adapted for passage of mainstream smoke through the section of filter material while substantially avoiding contact of the portion of mainstream smoke therein with the smoke-altering material. The provision of a portion of mainstream smoke substantially unaltered by the smoke-altering material can be useful to retain certain desirable taste and other sensory properties of the mainstream smoke.

Abstract: A cigarette includes lighting and mouth ends. It may include a smokable segment disposed at the lighting end. It also includes a mouth-end segment; an aerosol-generation system disposed between the lighting and mouth ends, which includes (i) a heat-generation segment adjacent the smokable segment, including a heat source and an insulation layer and (ii) an aerosol-generating segment including a substrate, which may include tobacco pellets and aerosol-forming material disposed in a substrate cavity between the heat generation segment and the mouth end; a piece of outer wrapping material that provides an overwrap around at least a portion of the aerosol-generating segment, the heat-generation segment, and at least a portion of the smokable segment and includes a foil strip laminated thereon; those segments being connected together by the overwrap to provide a cigarette rod; that is connected to the mouth-end segment using tipping material.

Abstract: A smoking article is provided including (a) a tobacco rod comprising a smokable filler material contained within a circumscribing outer wrapping material, wherein the smokable filler material comprises at least about 45% by weight flue-cured tobacco based on the total dry weight of the smokable filler material; (b) one or more inner wrapping strips positioned between the tobacco rod and the outer wrapping material and extending longitudinally along the tobacco rod and including a burley tobacco; and (c) a filter element connected to the tobacco rod, the filter element having an end proximal to the tobacco rod and an end distal from the tobacco rod, wherein the filter element includes at least one fibrous tow section of filter material, a general adsorbent, and an ion exchange resin.

Abstract: A filter element incorporating an adsorbent material is provided. The filter element may comprise a first section of filter material and a second section of filter material spaced apart to form a compartment therebetween. The compartment may be filled with one or more adsorbents or the compartment may be divided into two regions, wherein one compartment region is filled with an adsorbent and the other compartment region is either filled with an ion-exchange resin or remains empty. The section of filter material adjacent to the tobacco rod may include one or more channels therethrough for passaging smoke directly from the tobacco rod into the adsorbent-filled compartment. The mouth end section of filter material may contain a breakable capsule, wherein the breakable capsule is filled with a flavoring agent capable of altering the taste characteristics of mainstream smoke.

Abstract: A cigarette smoking article achieves very low levels of CO and other gas phase components by means of substantial air dilution, but has an acceptable pressure drop and sufficient delivery of particulate matter to provide a flavorful smoke. The filter has two sections, an upstream section which has substantially no pressure drop thereacross and a downstream section which provides substantially all the pressure drop of the filter. Dilution air is admitted to the upstream section of the filter to mix with mainstream smoke before it passes through the downstream section of the filter and thereby reduce the CO and gas phase levels in the smoke.