U.S. patent application number 14/332934 was filed with the patent office on 2015-01-29 for electronic smoking article.
The applicant listed for this patent is Altria Client Services Inc.. Invention is credited to Georgios D. Karles, San Li, Weiling Li.
Application Number | 20150027468 14/332934 |
Document ID | / |
Family ID | 51266448 |
Filed Date | 2015-01-29 |
United States Patent
Application |
20150027468 |
Kind Code |
A1 |
Li; San ; et al. |
January 29, 2015 |
ELECTRONIC SMOKING ARTICLE
Abstract
An electronic smoking article includes a reservoir including a
liquid aerosol formulation, a heater operable to at least partially
volatilize the liquid aerosol formulation and form an aerosol, and
a filter segment formed of polylactic acid fibers or a crimped
polylactic acid film. The filter segment includes at least one
additive and is positioned downstream of the heater.
Inventors: |
Li; San; (Midlothian,
VA) ; Karles; Georgios D.; (Richmond, VA) ;
Li; Weiling; (Moseley, VA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Altria Client Services Inc. |
Richmond |
VA |
US |
|
|
Family ID: |
51266448 |
Appl. No.: |
14/332934 |
Filed: |
July 16, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61858343 |
Jul 25, 2013 |
|
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Current U.S.
Class: |
131/329 |
Current CPC
Class: |
A24D 3/185 20130101;
A24D 3/048 20130101; A24D 3/063 20130101; A24F 47/008 20130101 |
Class at
Publication: |
131/329 |
International
Class: |
A24F 47/00 20060101
A24F047/00; A24D 3/04 20060101 A24D003/04; A24D 3/06 20060101
A24D003/06; A24D 3/18 20060101 A24D003/18 |
Claims
1. An electronic smoking article operable to produce an aerosol
comprising: a liquid aerosol formulation; a heater operable to at
least partially volatilize the liquid aerosol formulation and form
an aerosol; and a filter segment formed of polylactic acid fibers
or a crimped polylactic acid film, the filter segment including at
least one additive and being positioned downstream of the heater
and operable to elute the at least one additive into the aerosol as
the aerosol passes through the filter segment.
2. The electronic smoking article of claim 1, wherein the filter
segment has a length ranging from about 2 mm to about 30 mm and an
outer diameter that is about the same or less than an inner
diameter of an outer housing of the electronic smoking article.
3. The electronic smoking article of claim 1, wherein the
polylactic acid fibers are substantially parallel.
4. The electronic smoking article of claim 1, wherein the filter
segment is detachable and a sleeve is operable to attach the filter
segment to the electronic smoking article.
5. The electronic smoking article of claim 1, further including a
mouth end insert positioned downstream of the filter segment.
6. The electronic smoking article of claim 1, further including a
mouth end insert positioned upstream of the filter segment.
7. The electronic smoking article of claim 1, wherein the at least
one additive is selected from the group consisting of flavors,
aerosol modifiers, aromatic materials, pH modifying agents,
chemesthesis agents, volatile acids and combinations thereof.
8. The electronic smoking article of claim 1, wherein the at least
one additive is impregnated in the filter segment or included in a
coating on at least one surface of the filter segment.
9. The electronic smoking article of claim 1, wherein the at least
one additive is encapsulated or microencapsulated.
10. The electronic smoking article of claim 1, wherein the heater
comprises a capillary in fluid communication with a reservoir.
11. The electronic smoking article of claim 10, wherein the
reservoir is pressurized and includes a mechanically or
electrically operated valve at an outlet of the reservoir.
12. The electronic smoking article of claim 10, wherein the
reservoir is compressible such that the liquid material is manually
pumped to the capillary.
13. The electronic smoking article of claim 1, wherein the heater
is a coil heater in communication with a filamentary wick which
draws the liquid aerosol formulation from a reservoir via capillary
action.
14. The electronic smoking article of claim 13, wherein the
electronic smoking article further comprises: an outer tube
extending in the longitudinal direction; an inner tube within the
outer tube; and the reservoir comprising the liquid aerosol
formulation contained in an outer annulus between the outer tube
and the inner tube, wherein the coil heater is located in the inner
tube and the filamentary wick is in communication with the
reservoir and surrounded by the coil heater such that the
filamentary wick delivers the liquid aerosol formulation to the
coil heater and the coil heater heats the liquid aerosol
formulation to a temperature sufficient to vaporize the liquid
aerosol formulation and form an aerosol.
15. The electronic smoking article of claim 14, wherein the
electronic smoking article comprises a first section attachable to
a second section and wherein the filamentary wick, the reservoir
and filter segment are contained in the first section and a power
supply operable to apply voltage across the heater is contained in
the second section.
16. The electronic smoking article of claim 1, wherein the at least
one additive is dispersed substantially uniformly throughout the
filter segment.
17. The electronic smoking article of claim 1, wherein a
concentration of the at least one additive varies along a length of
the filter segment.
18. The electronic smoking article of claim 7, wherein the volatile
acid is pyruvic acid.
19. The electronic smoking article of claim 7, wherein the volatile
acid is operable to reduce a pH of the aerosol to a pH ranging from
about 4 to about 8.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. provisional Application No. 61/858,343, filed
on Jul. 25, 2013, the entire content of which is incorporated
herein by reference thereto.
WORKING ENVIRONMENT
[0002] Many of the embodiments disclosed herein include electronic
smoking articles operable to deliver liquid from a liquid supply
source to a heater. The heater volatilizes a liquid to form an
aerosol.
SUMMARY OF SELECTED FEATURES
[0003] An electronic smoking article, such as an electronic smoking
article, operable to produce an aerosol includes a liquid aerosol
formulation, a heater operable to at least partially volatilize the
liquid aerosol formulation and form an aerosol, and a filter
segment formed of polylactic acid fibers or a crimped polylactic
acid film. The filter segment includes at least one additive and is
positioned downstream of the heater. The filter segment is operable
to elute the at least one additive into the aerosol as the aerosol
passes through the filter segment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a side view of an electronic smoking article
constructed according to the teachings herein.
[0005] FIG. 2 is a cross-sectional view of an electronic smoking
article according to a first embodiment.
[0006] FIG. 3 is a cross-sectional view of another embodiment of an
electronic smoking article according to a second embodiment.
[0007] FIG. 4 is a cross-sectional view of an electronic smoking
article according to a third embodiment.
[0008] FIG. 5 is a perspective view of a filter segment as
described herein.
[0009] FIG. 6 is a cross-sectional view of an electronic smoking
article according to a fourth embodiment including the filter
segment of FIG. 5.
[0010] FIG. 7 is a perspective view of a detachable filter
segment.
[0011] FIG. 8 is a cross-sectional view of an electronic smoking
article according to a fifth embodiment including the detachable
filter segment of FIG. 7.
DETAILED DESCRIPTION
[0012] An electronic smoking article includes a liquid supply
(reservoir) containing a liquid aerosol formulation. The liquid
aerosol formulation is delivered to a heater where the liquid
aerosol formulation is heated, volatilized, and forms an aerosol.
As used herein, the term "electronic smoking article" is inclusive
of all types of electronic smoking articles, regardless of form,
size or shape, including electronic cigarettes, electronic cigars,
electronic pipes, electronic hookahs and the like. The liquid
aerosol formulation can include nicotine or be nicotine free.
Moreover, the liquid aerosol formulation can include tobacco
flavors or instead, or in combination include other suitable
flavors.
[0013] Preferably, the aerosol passes through a filter segment
formed of a low efficiency filter material, such as polylactic acid
(PLA) in the form of a rod. Preferably, the filter includes PLA
fibers that are arranged such that the fibers are substantially
parallel and have a plurality of passages therebetween and/or a
crimped PLA film having hollow channels extending parallel to the
direction of the aerosol flow so as to allow for minimal resistance
to draw and minimal aerosol filtration. Accordingly, as the aerosol
passes through the PLA filter segment, additives, such as flavors
and/or volatile acids, are eluted into the aerosol so as to alter
the sensory experience of the aerosol. Moreover, the composition
and arrangement of the fibers in the filter segment results in
minimal resistance to aerosol flow therethrough and/or minimal
filtration of the aerosol. The type of additives, location of the
additives in the filter, composition of the additives, and the like
can be altered to provide controlled release of additives into the
aerosol as it passes through the filter segment.
[0014] Preferably, as shown in FIGS. 2, 3, 4, 6, and 8, the
electronic smoking article 60 comprises a replaceable cartridge (or
first section) 70 and a reusable fixture (or second section) 72,
which are coupled together at a threaded joint 74 or by other
convenience such as a snug-fit, snap-fit, detent, clamp and/or
clasp.
[0015] As shown in FIG. 3, the first section 70 can house a
mouth-end insert 20, the filter segment 600, a capillary aerosol
generator including a capillary (capillary tube) 18, a heater 19 to
heat at least a portion of the capillary 18, a reservoir 14 and
optionally a valve 40. Alternatively, as shown in FIG. 4, the first
section 70 can house a mouth end insert 20, the filter segment 600,
a heater 319, a flexible, filamentary wick 328 and a reservoir 314
as discussed in further detail below.
[0016] The second section 72 can house a power supply 12 (shown in
FIGS. 2, 3 and 4), control circuitry 11, and optionally a puff
sensor 16 (shown in FIGS. 3 and 4). The threaded portion 74 of the
second section 72 can be connected to a battery charger when not
connected to the first section 70 for use so as to charge the
battery.
[0017] As shown in FIG. 2, the electronic smoking article 60 can
also include a middle section (third section) 73, which can house
the reservoir 14, heater 19 and valve 40. The middle section 73 can
be adapted to be fitted with a threaded joint 74' at an upstream
end of the first section 70 and a threaded joint 74 at a downstream
end of the second section 72. In this embodiment, the first section
70 houses the mouth-end insert 20 and the filter segment 600, while
the second section 72 houses the power supply 12 and control
circuitry.
[0018] Preferably, the first section 70, the second section 72 and
the optional third section 73 include an outer cylindrical housing
22 extending in a longitudinal direction along the length of the
electronic smoking article 60. In one embodiment, the middle
section 73 is disposable and the first section 70 and/or second
section 72 are reusable. In another embodiment, the first section
70 can also be replaceable so as to avoid the need for cleaning the
capillary 18 and/or heater 19. The sections 70, 72, 73 can be
attached by threaded connections whereby the middle section 73 can
be replaced when the reservoir 14 is used up.
[0019] In another embodiment, the housing 22 may comprise a single,
unitary tube, without any threaded connections.
[0020] As shown in FIG. 2, the outer cylindrical housing 22 can
include a cutout or depression 102 which allows a smoker (vaporer)
to manually apply pressure to the reservoir 14. Preferably, the
outer cylindrical housing 22 is flexible and/or compressible along
the length thereof and fully or partially covers the reservoir 14.
The cutout or depression 102 can extend partially about the
circumference of the outer cylindrical housing 22. The reservoir 14
is compressible such that when pressure is applied to the
reservoir, liquid is pumped from the reservoir 14 to the capillary
18. A pressure activated switch 44 can be positioned beneath the
reservoir 14. When pressure is applied to the reservoir 14 to pump
liquid, the switch is also pressed and a heater 19 is activated.
The heater 19 can be a portion of the capillary 18.
[0021] In the embodiment of FIG. 2, the reservoir 14 is a tubular,
elongate body formed of an elastomeric material so as to be
flexible and/or compressible when squeezed. Preferably, the
elastomeric material can be selected from the group consisting of
silicone, plastic, rubber, latex, and combinations thereof.
[0022] Preferably, the compressible reservoir 14 has an outlet 16
which is in fluid communication with a capillary 18 so that when
squeezed, the reservoir 14 can deliver a volume of liquid material
to the capillary 18. Simultaneous to delivering liquid to the
capillary, the power supply 12 is activated upon application of
manual pressure to the pressure switch and the capillary 18 is
heated to form a heated section wherein the liquid material is
volatilized. Upon discharge from the heated capillary 18, the
volatilized material expands, mixes with air and forms an
aerosol.
[0023] Preferably, the reservoir 14 extends longitudinally within
the outer cylindrical housing 22 of the first section 70 (shown in
FIGS. 3 and 4) or the middle section 73 (shown in FIG. 2). The
reservoir 14 comprises a liquid aerosol formulation which is
volatilized when heated and forms an aerosol when discharged from
the capillary 18.
[0024] In the preferred embodiments of FIGS. 2 and 3, the capillary
18 includes an inlet end 62 in fluid communication with the outlet
16 of the reservoir 14, and an outlet end 63 operable to expel
volatilized liquid material from the capillary 18. In a preferred
embodiment, as shown in FIGS. 2 and 3, the reservoir 14 may include
a valve 40.
[0025] As shown in FIG. 2, the valve 40 can be a check valve that
is operable to maintain the liquid material within the reservoir,
but opens when the reservoir 14 is squeezed and pressure is
applied. Preferably, the check valve 40 opens when a critical,
minimum pressure is reached so as to avoid inadvertent dispensing
of liquid material from the reservoir 14 or activating the heater
19. Once pressure upon the reservoir 14 is relieved, the valve 40
closes. The heated capillary 18 discharges liquid remaining
downstream of the valve 40.
[0026] As shown in FIG. 3, in other embodiments, the valve 40 can
be a two-way valve and the reservoir 14 can be pressurized. For
example, the reservoir 14 can be pressurized using a pressurization
arrangement 405 which applies constant pressure to the reservoir
14. For example, pressure can be applied to the reservoir 14 using
an internal or external spring and plate arrangement which
constantly applies pressure to the reservoir 14. Alternatively, the
reservoir 14 can be compressible and positioned between two plates
that are connected by springs or the reservoir 14 could be
compressible and positioned between the outer housing and a plate
that are connected by a spring so that the plate applies pressure
to the reservoir 14.
[0027] Preferably, the capillary 18 of FIGS. 2 and 3 has an
internal diameter of 0.01 to 10 mm, preferably 0.05 to 1 mm, and
more preferably 0.05 to 0.4 mm. Also preferably, the capillary 18
may have a length of about 5 mm to about 72 mm, more preferably
about 10 mm to about 60 mm or about 20 mm to about 50 mm. In one
embodiment, the capillary 18 is substantially straight. In other
embodiments, the capillary 18 is coiled and/or includes one or more
bends therein to conserve space and/or accommodate a long
capillary.
[0028] In these embodiments, the capillary 18 is formed of a
conductive material, and thus acts as its own heater 19 by passing
current through the capillary. The capillary 18 may be any
electrically conductive material capable of being resistively
heated, while retaining the necessary structural integrity at the
operating temperatures experienced by the capillary 18, and which
is non-reactive with the liquid material. Suitable materials for
forming the capillary 18 are selected from the group consisting of
stainless steel, copper, copper alloys, porous ceramic materials
coated with film resistive material, Inconel.RTM. available from
Special Metals Corporation, which is a nickel-chromium alloy,
nichrome, which is also a nickel-chromium alloy, and combinations
thereof.
[0029] Alternatively, the capillary 18 may be a non-metallic tube
such as, for example, a glass tube having a conductive material
capable of being resistively heated, such as, for example,
stainless steel, nichrome or platinum wire, arranged there
along.
[0030] Preferably, at least two electrical leads 26 are bonded to a
metallic capillary 18 by brazing or crimping. Preferably, one
electrical lead 26 is attached to a first, upstream portion 101 of
the capillary 18 and a second electrical lead 26 is attached to a
downstream, end portion 104 of the capillary 18, as shown in FIGS.
2 and 3.
[0031] As noted above, the filter segment 600 can also be used in
an electronic smoking article including a heater 319 and a
filamentary wick 328 as shown in FIG. 4. The first section 70
includes an outer tube (or casing) 22 extending in a longitudinal
direction and an inner tube (or chimney) 362 coaxially positioned
within the outer tube 322. Preferably, a nose portion 361 of an
upstream gasket (or seal) 320 is fitted into an upstream end
portion 365 of the inner tube 362, while at the same time, an outer
perimeter 367 of the gasket 320 provides a liquid-tight seal with
an interior surface 397 of the outer casing 22. The upstream gasket
320 also includes a central, longitudinal air passage 315, which
opens into an interior of the inner tube 362 that defines a central
channel 321. A transverse channel 333 at an upstream portion of the
gasket 320 intersects and communicates with the central channel 315
of the gasket 320. This channel 333 assures communication between
the central channel 315 and a space 335 defined between the gasket
320 and a threaded connection 74.
[0032] Preferably, a nose portion 393 of a downstream gasket 310 is
fitted into a downstream end portion 381 of the inner tube 362. An
outer perimeter 382 of the gasket 310 provides a substantially
liquid-tight seal with an interior surface 397 of the outer casing
22. The downstream gasket 310 includes a central channel 384
disposed between the central passage 321 of the inner tube 362 and
the mouth end insert 20.
[0033] In this embodiment, the reservoir 314 is contained in an
annulus between an inner tube 362 and an outer casing 22 and
between the upstream gasket 320 and the downstream gasket 310.
Thus, the reservoir 314 at least partially surrounds the central
air passage 321. The reservoir 314 comprises a liquid material and
optionally a liquid storage medium (not shown) operable to store
the liquid material therein.
[0034] The inner tube 362 has a central air passage 321 extending
therethrough which houses the heater 319. The heater 319 is in
contact with the filamentary wick 328, which preferably extends
between opposing sections of the reservoir 314 so as to deliver the
liquid aerosol formulation from the reservoir to the heater
319.
[0035] Preferably, the electronic smoking article 60 of each
embodiment described herein also includes at least one air inlet
440. As shown in FIG. 4, the at least one air inlet 440 can be
located upstream of the heater 319.
[0036] In the embodiments shown in FIGS. 2 and 3, the at least one
air inlet 440 is arranged downstream of the capillary 18 so as to
minimize drawing air along the capillary and thereby avoid cooling
of the capillary 18 during heating cycles.
[0037] The power supply 12 of each embodiment can include a battery
arranged in the electronic smoking article 60. The power supply 12
is operable to apply voltage across the heater 19 associated with
the capillary 18, as shown in FIGS. 2 and 3, or the heater 319
associated with the filamentary wick 328, as shown in FIG. 4. Thus,
the heater 19, 319 volatilizes liquid material according to a power
cycle of either a predetermined time period, such as a 2 to 10
second period.
[0038] The battery can be a Lithium-ion battery or one of its
variants, for example a Lithium-ion polymer battery. Alternatively,
the battery may be a Nickel-metal hydride battery, a Nickel cadmium
battery, a Lithium-manganese battery, a Lithium-cobalt battery or a
fuel cell. In that case, preferably, the electronic smoking article
60 is smokable by a smoker until the energy in the power supply is
depleted. Alternatively, the power supply 12 may be rechargeable
and include circuitry allowing the battery to be chargeable by an
external charging device. The control circuitry 11 can be
programmable and can include an application specific integrated
circuit (ASIC). In other embodiments, the control circuitry 11 can
include a microprocessor programmed to carry out functions such as
heating the capillaries and/or operating the valves.
[0039] Preferably, the electronic smoking article 60 of each
embodiment also includes control circuitry which can be on a
printed circuit board 11 (shown in FIGS. 2, 3 and 4). The control
circuitry 11 can also include a heater activation light 27 (shown
in FIGS. 2, 3 and 4) that is operable to glow when the heater 19,
319 is activated.
[0040] As shown in FIGS. 2, 3, 4, 6, 8 and 9 the electronic smoking
article 60 includes the filter segment 600 at a location downstream
of the heater 19, 319. In one embodiment, the filter segment 600 is
constructed from polylactic acid fibers. The polylactic acid fibers
are arranged parallel to one another so that the aerosol flows
through channels between the fibers with minimal resistance. In
another embodiment, the filter segment 600 is constructed from a
crimped polylactic acid film having hollow channels extending
parallel to the direction of the aerosol flow so as to allow for
minimal resistance to draw and minimal filtration of the aerosol.
Thus, the filter segment 600 is an ultra low efficiency filter that
is designed primarily to deliver flavors and other additives, such
as volatile acids, to the aerosol rather than to filter particles
and/or aerosol constituents therefrom. In other embodiments, the
filter segment 600 could be formed of other films or planar
structures made from extrusion of thermoplastic polymers, paper or
stiff nonwoven structures that can be crimped so as to effectively
result in filtering segments having hollow channels therein.
[0041] Preferably, the filter segment 600 is about 2 mm to about 30
mm in length. More preferably, the filter segment 600 is about 5 mm
to about 25 mm in length (e.g., about 10 to about 20 nun or about
12 to about 18 mm). In addition, the outer diameter of the filter
segment 600 is about the same or less than the diameter of the
electronic smoking article 60.
[0042] In the preferred embodiment, the filter segment 600
minimizes resistance to draw (RTD) in the electronic smoking
article 60 and can be included inside the first section 70 during
manufacture or can be a detachable filter segment, as shown in
FIGS. 7 and 8, for addition to the electronic smoking article 60 if
desired by the smoker.
[0043] As shown in FIGS. 7 and 8, a sleeve portion 604 designed to
fit around the outer perimeter of the mouth end of the electronic
smoking article 60 and around a portion of the filter segment 600
can be used so attach and detach the filter segment 600 from the
electronic smoking article 60. The sleeve portion 604 can be sized
to friction fit with the filter segment 600 and with a mouth end of
the electronic smoking article 60. The sleeve portion 604 can be
colored, scented or include indicia thereon.
[0044] As shown in FIG. 6, the electronic smoking article 60 can
include the filter segment 600 at the mouth end of the electronic
smoking article 60, and no additional mouth end insert is included.
In other embodiments, as shown in FIG. 4, a mouth end insert 20 can
be positioned downstream of the filter segment 600. Alternatively,
the mouth end insert 20 can be positioned upstream of the filter
segment 600 as shown in FIG. 8.
[0045] In a preferred embodiment, additives including flavors,
nicotine, volatiles acids, and/or aerosol modifiers can be applied
to the filter segment 600 so that additives are eluted into the
aerosol as the aerosol passes therethrough. Suitable additives
include those disclosed in co-pending patent application Ser. No.
13/755,616, filed Jan. 31, 2013, the entire content of which is
incorporated herein in its entirety by reference thereto. Any
additives included in the filter segment 600 can also be included
in the liquid aerosol formulation. Alternatively, different
additives are included in the filter segment 600 and the liquid
aerosol formulation.
[0046] Preferred additives also include volatile acids. When
volatile acids are eluted into the aerosol, the pH of the aerosol
of the aerosol is lowered and the volatile acid reacts with vapor
phase nicotine to reduce any perceived harshness of the aerosol. In
one embodiment, nicotine in the aerosol can react with an acid to
form a nicotine salt in the particulate phase of the aerosol.
[0047] For example, the additives can be applied as a coating 606
(shown in FIG. 8) on an outer surface of the filter segment 600 or
the flavors and/or aerosol modifiers can be impregnated in the
filter segment 600. The additives can be microencapsulated with
water soluble materials having varying levels of water solubility
so as to provide controlled release of the additive over a period
of time. Moreover, the additives can be chosen to provide a
preferred flavor profile. When the filter segment 606 includes the
coating 606 and is impregnated with additives, the coating 606
includes the same additive as that impregnated in the filter
segment 600 or different additives. By including an
additive-containing coating 606 along with the additives
impregnated in the filter segment 600, release of the additives can
be staggered during smoking (vaping) and/or multiple additives can
be delivered.
[0048] As used herein, the term "additive" means any material or
component which modifies the characteristics of the electronic
smoking article 60 when the electronic smoking article 60 is smoked
(vaped). Any appropriate additive material or combination of
materials may be contained in the filter segment 600. Such additive
materials include flavor materials, aromatic materials, pH
modifying agents, volatile acids, chemesthesis agents including
cooling agents and warming agents, carbon dioxide formers,
commercially available flavor systems, nicotine in liquid, salt or
powder form, and other smoke modifiers.
[0049] When formed of a crimped PLA film, the filter segment 600
can be coated with additives prior to being crimped. The additives
can be liquid or particulate form, and can be added to the filter
segment 600 before or after crimping, by impregnation or infusion
of the additives facilitated by, for example, spraying. Liquid
additives can be held in pleats of a crimped filter segment 600 by
capillary forces. The additives may also be combined in solution or
mixture with an extrudable polymer, such as PLA, prior to forming
the flavored and/or additive laden filter segment 600.
[0050] As used herein, the term "flavor material" means any liquid
or solid flavor containing material or formulation that can release
flavors and/or aromas into the aerosol stream. Suitable flavors or
flavorings include, but are not limited to, menthol, mint, such as
peppermint and spearmint, chocolate, licorice, citrus and other
fruit flavors, gamma octalactone, vanillin, ethyl vanillin, breath
freshener flavors, spice flavors such as cinnamon, methyl
salicylate, linalool, bergamot oil, geranium oil, lemon oil, ginger
oil, and tobacco flavor. Other suitable flavors may include flavor
compounds selected from the group consisting of an acid, an
alcohol, an ester, an aldehyde, a ketone, a pyrazine, combinations
or blends thereof and the like.
[0051] The flavor material can be in the form of particles,
granules, fibers, capsules, microcapsules, powders, crushed plant
material, aromatic barks, seeds, pieces of dried fruits and/or root
material, or any other suitable form. For example, the flavor
material can include tobacco beads, flavor beads, mentholated
flavor beads, flavor capsules and other flavor materials as used in
traditional tobacco smoke filters.
[0052] Suitable flavor materials can be non-volatile or volatile
and can be delivered to the mouth via the condensation of the
aerosol in the filter followed by entrapment and/or dissolution of
the flavor material in droplets and/or deposition of the droplets
to the tongue of the smoker during a puff. The droplets can consist
of constituents used to form the aerosol including propylene
glycol, glycerin, water and optionally nicotine. The flavor
material can be released into the aerosol and/or can be delivered
to a smoker's mouth via contact with moisture from the smoker's
lips.
[0053] The flavor materials can provide a bitter taste. Suitable
compounds which provide a bitter taste include, without limitation,
caffeine, denatonium benzoate, theobromine, quinine, and
naringin.
[0054] The flavor materials can provide a sour taste. Suitable
compounds which provide a sour taste include, without limitation,
citric acid, malic acid, succinic acid and tartaric acid.
[0055] The flavor materials can provide a salty taste. Suitable
compounds which provide a salty taste include, without limitation,
sodium chloride and potassium chloride.
[0056] The flavor materials can provide a sweet taste. Suitable
compounds which provide a sweet taste include, without limitation,
carbohydrates, including sucrose, and high intensity sweeteners,
including sucralose and saccharin.
[0057] The flavor materials can provide umami and mouth feel.
Suitable compounds which provide umami and mouth feel include,
without limitation, monosodium glutamate, gamma-glutamyl peptides,
such as gamma-glutamycysteine-beta-alanine, (R)-strombine.
[0058] The flavorant can be added to the filter segment 600 in an
amount ranging from about 0.2% to about 15% by weight (e.g., about
1% to about 12%, about 2% to about 10%, or about 5% to about 8%).
The at least one flavorant can be a natural flavorant or an
artificial flavorant.
[0059] In one embodiment, the additive can be a chemesthesis agent
and/or can be chosen to alter the mouthfeel of the aerosol. For
example, the additive can be a chemesthesis agent that provides a
warm, tingling sensation and/or a cooling sensation. Additives such
as capsaicin, piperine, alpha-hydroxy-sanshool, and (8)-gingerole
can be included to provide a warm, tingling or burning sensation.
Additives including menthol, menthyl lactate, WS-3
(N-Ethyl-p-menthane-3-carboxamide), WS-23
(2-Isopropyl-N,2,3-trimethylbutyramide) and Evercool 180.TM. can be
included to provide a cooling sensation. In addition, the additive
can include extracts, such as coffee extract, red pepper extract,
ginger extract and peppermint oil.
[0060] During smoking, as aerosol travels through the filter
segment 600, additives impregnated in and/or coated on the filter
segment can be at least partially eluted into the aerosol for
delivery to the smoker. The concentration of additives in the
filter segment 600 can be varied depending on the desired strength
of the flavor and/or additives. In addition, additives entrained
within channels of the filter segment 600 can be subjected to
physical dislodgement and entrainment in the aerosol flow.
[0061] Preferably, the filter segment 600 is located far enough
downstream of the heater 19, 319 so as to minimize heat exposure of
the additives and substantially prevent degradation thereof. Also
preferably, the filter segment 600 is located so that the filter
segment 600 and/or additives contained therein are not exposed to
temperatures above about 150.degree. C.
[0062] In one embodiment, the at least one additive can include at
least one volatile acid, such as pyruvic acid. When pyruvic acid or
other volatile acids are included in the filter segment, the acid
is eluted into the aerosol and lowers the pH thereof. Accordingly,
the vapor phase nicotine of the aerosol is also lowered and harsh
sensory perceptions are reduced.
[0063] Also preferably, the acid is included in the filter segment
600 in an amount sufficient to reduce the pH of the aerosol to a pH
ranging from about 4 to about 8, more preferably about 5 to about 7
or about 5.5 to about 6.5.
[0064] Preferably, the acid is added to the filter segment 600 in a
solution including the acid in an amount ranging from about 0.1% by
weight to about 25% by weight (e.g., about 1% to about 20%, about
2% to about 15%, about 3% to about 10% or about 4% to about
8%).
[0065] For example, the filter segment 600 can be a PLA filter plug
having a length of about 7 mm. The filter plug can be coated with a
solution of 20% pyruvic acid in an 80:20 ratio of glycerin to
water. The PLA filter plug can be attached to the electronic
cigarette to produce an aerosol having a milder and less irritating
effect on the throat as compared to electronic cigarettes not
including such a filter segment.
[0066] In another example, the filter segment 600 can be a PLA
filter plug coated with a solution of 20% menthol in a mixture of
50:50 propylene glycol and glycerol to provide an aerosol having a
sensation and flavor of menthol.
[0067] In yet another example, the filter segment 600 can be a PLA
filter plug having a small amount of flavor in a 50:50 propylene
glycol and glycerol mixture applied thereto to provide a flavored
aerosol.
[0068] As shown in FIGS. 2, 3, 4, and 8, the electronic smoking
article 60 can further include the mouth-end insert 20 having at
least two off-axis, preferably diverging outlets 21. Preferably, as
shown in FIGS. 2, 3, and 4, the mouth-end insert is located
downstream of the filter segment 600. In other embodiments, as
shown in FIG. 8, the filter segment 600 can be downstream of the
mouth-end insert 20.
[0069] Preferably, the mouth-end insert 20 includes at least two
diverging outlets 21. (e.g. 3, 4, 5, or preferably 6 to 8 outlets
or more). Preferably, the outlets 21 of the mouth-end insert 20 are
located at ends of off-axis passages 23 and are angled outwardly in
relation to the longitudinal direction of the electronic smoking
article 60 (i.e., divergently). As used herein, the term "off-axis"
denotes at an angle to the longitudinal direction of the electronic
smoking article.
[0070] In a preferred embodiment, the electronic smoking article 60
is about the same size as a conventional smoking article. In some
embodiments, the electronic smoking article 60 can be about 80 mm
to about 110 mm long, preferably about 80 mm to about 100 mm long
and about 7 mm to about 8 mm in diameter. For example, in an
embodiment, the electronic smoking article is about 84 mm long and
has a diameter of about 7.8 mm.
[0071] The outer cylindrical housing 22 of the electronic smoking
article 60 may be formed of any suitable material or combination of
materials. Preferably, the outer cylindrical housing 22 is formed
of metal and is part of the electrical circuit.
[0072] Preferably, the liquid aerosol formulation for use in each
of the electronic smoking articles 60 described herein includes at
least one aerosol former, optionally water, and flavors. The liquid
aerosol formulation can include nicotine or be nicotine free.
Moreover, the liquid aerosol formulation can include tobacco
flavors or other suitable flavors.
[0073] In the preferred embodiment, the at least one aerosol former
is selected from the group consisting of propylene glycol, glycerin
and combinations thereof. Preferably, the at least one aerosol
former is included in an amount ranging from about 40% by weight
based on the weight of the liquid formulation to about 90% by
weight based on the weight of the liquid formulation (e.g., about
50% to about 80%, about 55% to about 75% or about 60% to about
70%).
[0074] Preferably, the liquid formulation also includes water.
Water can be included in an amount ranging from about 5% by weight
based on the weight of the liquid formulation to about 20% by
weight based on the weight of the liquid formulation, more
preferably in an amount ranging from about 10% by weight based on
the weight of the liquid formulation to about 15% by weight based
on the weight of the liquid formulation.
[0075] The liquid aerosol formulation optionally includes at least
one flavorant in an amount ranging from about 0.2% to about 15% by
weight (e.g., about 1% to about 12%, about 2% to about 10%, or
about 5% to about 8%). The at least one flavorant can be a natural
flavorant or an artificial flavorant. Preferably, the at least one
flavorant is selected from the group consisting of tobacco flavor,
menthol, wintergreen, peppermint, herb flavors, fruit flavors, nut
flavors, liquor flavors, and combinations thereof.
[0076] When the word "about" is used in this specification in
connection with a numerical value, it is intended that the
associated numerical value include a tolerance of .+-.10% around
the stated numerical value. Moreover, when reference is made to
percentages in this specification, it is intended that those
percentages are based on weight, i.e., weight percentages.
[0077] Moreover, when the words "generally" and "substantially" are
used in connection with geometric shapes, it is intended that
precision of the geometric shape is not required but that latitude
for the shape is within the scope of the disclosure. When used with
geometric terms, the words "generally" and "substantially" are
intended to encompass not only features which meet the strict
definitions but also features which fairly approximate the strict
definitions.
[0078] It will now be apparent that a new, improved, and nonobvious
electronic smoking article has been described in this specification
with sufficient particularity as to be understood by one of
ordinary skill in the art. Moreover, it will be apparent to those
skilled in the art that numerous modifications, variations,
substitutions, and equivalents exist for features of the electronic
smoking article which do not materially depart from the spirit and
scope of the invention. Accordingly, it is expressly intended that
all such modifications, variations, substitutions, and equivalents
which fall within the spirit and scope of the invention as defined
by the appended claims shall be embraced by the appended
claims.
* * * * *