U.S. patent application number 16/616321 was filed with the patent office on 2020-04-16 for tobacco-containing consumable for aerosol generating devices.
This patent application is currently assigned to ELucid8 Holdings Ltd.. The applicant listed for this patent is ELucid8 Holdings Ltd.. Invention is credited to Jason Hopps, David Mclaughlin.
Application Number | 20200113227 16/616321 |
Document ID | / |
Family ID | 59220585 |
Filed Date | 2020-04-16 |
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United States Patent
Application |
20200113227 |
Kind Code |
A1 |
Mclaughlin; David ; et
al. |
April 16, 2020 |
Tobacco-Containing Consumable For Aerosol Generating Devices
Abstract
A non-combustible tobacco article for use in conjunction with a
heat source to produce an inhalable aerosol includes at least one
tobacco derived portion, at least one distal filter portion and at
least one mouth-end filter portion held together in an overwrap;
the complete article having a compressibility factor in the
longitudinal axis of <10%.
Inventors: |
Mclaughlin; David;
(Ballymena, Co. Antrim, GB) ; Hopps; Jason;
(Ballymena, Co. Antrim, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ELucid8 Holdings Ltd. |
Ballymena |
|
GB |
|
|
Assignee: |
ELucid8 Holdings Ltd.
Ballymena
GB
|
Family ID: |
59220585 |
Appl. No.: |
16/616321 |
Filed: |
May 24, 2018 |
PCT Filed: |
May 24, 2018 |
PCT NO: |
PCT/GB2018/051416 |
371 Date: |
November 22, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24D 3/0225 20130101;
A24D 3/17 20200101; A24D 3/0287 20130101; A24D 1/20 20200101; A24F
40/465 20200101; A24F 47/008 20130101 |
International
Class: |
A24D 3/17 20060101
A24D003/17; A24F 40/465 20060101 A24F040/465; A24D 3/02 20060101
A24D003/02; A24D 1/20 20060101 A24D001/20 |
Foreign Application Data
Date |
Code |
Application Number |
May 24, 2017 |
GB |
1708331.2 |
Claims
1. A non-combustible tobacco article for use in conjunction with a
heat source to produce an inhalable aerosol, the article comprising
at least one tobacco derived portion, at least one distal filter
portion and at least one mouth-end filter portion held together
along a longitudinal axis in an overwrap; the complete article
having a compressibility factor in the longitudinal axis of
<10%, the compressibility factor being measured in the
longitudinal axis by application of a force of 10 Newtons at ends
of the article and measuring deflection distance as a percentage of
total length of the article.
2. The tobacco article according to claim 1 arranged to have a
total pressure drop <120 mm water column across the article in
the longitudinal axis.
3. The tobacco article according to claim 1 arranged such that in
use the article modifies a first aerosol produced by the heat
source to produce the inhalable aerosol.
4. The tobacco article according to claim 1 arranged such that in
use the article provides volatile components to the inhalable
aerosol upon action of the heat source.
5. The tobacco article according to claim 1 further comprising
induction elements dispersed within the at least one tobacco
derived portion such that, in use, electromagnetic energy can be
applied to the induction elements to generate heat.
6. The tobacco article according to claim 1 where the at least one
tobacco derived portion contains at least one from the group of a
flavourant, a humectant and a pH modifying agent.
7. The tobacco article according to claim 1 where the at least one
tobacco derived portion contains a flavourant, a humectant and a pH
modifying agent.
8. The tobacco article according to claim 1 where the overwrap
includes at least one transparent region.
9. The tobacco article according to claim 1 where the overwrap is
arranged to resist absorbing volatile and aerosol components in the
at least one tobacco derived portion such that the total weight
gain by absorption after use is <10% of the original overwrap
weight.
10. The tobacco article according to claim 1 where the overwrap is
wound in a helical direction relative to the longitudinal axis of
the article.
11. The tobacco article according to claim 1 where the at least one
mouth-end filter portion comprises at least two distinct regions
abutted together.
12. The tobacco article according to claim 1 where the at least one
mouth-end filter portion and the at least one distal filter portion
separately or combined contain at least one from the group of an
aesthetic element, a flavourant and an attenuant.
13. The tobacco article according to claim 1 where the at least one
mouth-end filter portion and the at least one distal filter portion
separately or combined contain a flavourant and an aesthetic
element.
14. The tobacco article according to claim 1 where the at least one
mouth-end filter portion and the at least one distal filter portion
separately or combined contain an attenuant, a flavourant and an
aesthetic element.
15. The tobacco article according to claim 1 where at least one of
the at least one mouth-end filter portion and the at least one
distal filter portion contains at least one airflow channel in the
longitudinal axis.
16. A process of manufacturing a tobacco article, the method
comprising the steps of: forming at least one distal filter portion
and at least one mouth-end filter portion; arranging said filter
portions within an overwrap in such a manner to form a cavity
between the at least one distal filter portion and the at least one
mouth-end filter portion; filling the cavity with tobacco derived
material; and closing the overwrap material to form an integral
unit.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a national phase entry under 35
U.S.C. .sctn. 371 of International Application No.
PCT/GB2018/051416, filed May 24, 2018, published in English, which
claims priority to Great Britain Patent Application No. 1708331.2,
filed May 24, 2017, the disclosures of which are incorporated
herein by reference.
BACKGROUND OF THE INVENTION
[0002] Many alternatives to traditional combustible tobacco
products have been launched in recent years.
[0003] Electronic Cigarettes use battery power to heat a
nicotine-containing aerosol-generating liquid to form an inhalable
nicotine-containing aerosol. Such products tend not to contain
tobacco.
[0004] Heated Tobacco Products use various energy sources and means
to heat a tobacco-containing consumable to generate an inhalable
aerosol that contains some components derived from tobacco,
including flavour and nicotine.
[0005] There are also various "hybrid" products which can combine
technology from both electronic cigarettes and Heated Tobacco
Products in order to generate an inhalable nicotine-containing
aerosol wherein flavour and nicotine can originate from either the
aerosol-generating liquid or the tobacco portions.
[0006] Specific examples of existing technologies include:
[0007] WO9639880 and WO2013190036 describe a cigarette-like
cylindrical consumable article, with a distal end containing
tobacco-derived material, typically crimped reconstituted tobacco
sheet, a mouth-end filter typically containing multiple segments,
and an overwrap made from paper. Said article is intended to be
electrically heated in order to produce an inhalable
nicotine-containing aerosol.
[0008] WO2016207407 also describes a tobacco consumable intended
for consumption by heating, namely a distal tobacco-derived
portion, a mouth-end filter and a paper overwrap.
[0009] US2009151717 describes a small metallic capsule ("pod") with
a foil lid that is pierced prior to use. Inside the pod, the
tobacco-derived material typically comprises finely ground tobacco
particles, humectants and flavourings.
[0010] WO2016159013 describes a device in which an aerosol is
generated by heating a liquid which is then passed through a
separate tobacco portion; the tobacco portion imparts flavour
and/or nicotine to the final aerosol. The tobacco portion can be
held within a moulded plastic capsule with a mesh at the distal end
and a small filter at the mouth-end.
[0011] WO2016135342 describes a product which operates in a similar
manner to that described in WO2016159013, however the tobacco
portion and the liquid heating unit are comprised as one unit. The
tobacco portion is held within a moulded plastic structure with a
filter at the mouth-end.
[0012] With regards to the consumable units for these products,
there are some recognised limitations.
[0013] For example, with consumables manufactured using
cigarette-rod-making technology the user can mistakenly ignite the
consumable and potentially inhale unintended and or undesirable
combustion products. Also, consumables utilising plastic or metal
capsules require bespoke manufacturing machinery, have limited
environmental recyclability, and have high material &
manufacturing costs.
BRIEF SUMMARY OF THE INVENTION
[0014] The current invention describes a tobacco-containing
consumable article for use in aerosol-generating devices comprising
at least a tobacco-derived portion, a distal filter portion and a
mouth-end filter portion held together in a continuous overwrap,
with a compressibility factor less than 10%.
[0015] The article may have a total pressure drop <120 mm water
column along its longitudinal axis. The pressure drop is preferably
in the range of 5 to 40 mm water column and more preferably is in
the range 10 to 30 mm water column. Such a consumable may be
manufactured using conventional cavity-filter-making technology,
well known within the tobacco industry and shown in U.S. Pat. No.
6,537,186 for example. In such prior art arrangements, a filter is
manufactured with a distal filter portion, a cavity to receive
typically a solid granular material such as activated carbon, and a
mouth-end filter portion all held together by a paper overwrap.
Products have also existed which utilised tobacco-derived material
within said cavity to impart or attenuate flavour to the smoke as
it passes through the filter.
[0016] The current invention therefore allows production of
consumables via readily-available high-speed production machinery,
using proven manufacturing technology, with low material and
production costs, material & design flexibility, and can be
compatible with a variety of aerosol-generating systems.
[0017] In some examples, the article may modify one or more other
organoleptic properties of the aerosol (e.g. modifying the feel or
smell or look of the aerosol to the user).
[0018] In some examples, the article may comprise a substance that
modifies the PH of the aerosol by either lowering or raising the PH
(e.g. modifying the acidity or the basicity of the aerosol).
[0019] In some examples, the article may modify (e.g. reduce) the
amount of aldehydes in the aerosol.
[0020] As described herein, a non-combustible tobacco article means
an article containing a tobacco-derived portion that is not
intended to be combusted as a whole or in part during use, and no
part of said article is intended to be lit during use. Furthermore
the construction of said article resists ignition through the use
of filter materials such as cellulose acetate at both the distal
and mouth ends.
[0021] The term aerosol shall be interpreted to include gas,
vapour, droplets, condensates, particulates and combinations
thereof. An inhalable aerosol shall mean an aerosol with an average
particle size as measured by laser dispersion ranging from 0.1 to
10 .mu.m, more preferably 0.1 to 1.5 .mu.m.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Examples of the present invention will now be described with
reference to the accompanying drawings, in which:
[0023] FIG. 1 is a side schematic view of an article according to
the invention;
[0024] FIG. 2 is a side schematic view of an article according to
the invention showing the longitudinal axis;
[0025] FIG. 3 is a side perspective view of an example filter
portion and overwrap for use in the invention employing multiple
layers in its overwrap;
[0026] FIGS. 4, 5 and 6 are side schematic views of example
articles according to the invention with different overwrap
configurations;
[0027] FIGS. 7 and 8 are schematic views of a device employed in
combination with the article of the invention;
[0028] FIG. 9 shows an example filter portion that can be employed
in the article of the invention; and
[0029] FIG. 10 is a schematic view of an alternative method of
employing the article of the invention to generate vapour.
DETAILED DESCRIPTION
[0030] FIG. 1 depicts the basic construction of the article of the
invention. The mouth end 3 is the end of the article intended as
the exit of the aerosol towards the user. The distal end 1 is the
opposite end of the article, typically intended as the inlet for
air and other materials into the article. A tobacco portion sits
there between. By way of example, the length of the tobacco portion
2 is in the range 7 mm to 17 mm and preferably in the range 10 mm
to 13 mm, the length of each of the filter portions 1,3 is in the
range 3 mm to 15 mm and preferably in the range 4 mm to 6 mm and
the diameter of the flavour container is in the range 5 mm to 8.5
mm. The dimensions depend upon a combination of the need to provide
sufficient material within the tobacco portion 2 to provide a
desired flavour effect whilst ensuring a balance between the three
sections overall to provide an appropriate pressure drop whilst
retaining overall product strength and compressibility.
[0031] In the example of FIG. 1 part 2 is a tobacco-derived
portion, which can include single-grade tobacco, blended tobacco
grades, leaf, stem, dust, reconstituted tobacco, washed tobacco,
extracted tobacco, treated tobacco, tobacco extracts and mixtures
thereof. The tobacco-derived portion 2 can be produced from tobacco
plants by methods including harvesting, drying, cutting, shredding,
grinding, extraction, reconstitution, extrusion and combinations
thereof. The tobacco-derived portion 2 can be present in the
physical form of leaf, stem, dust, reconstituted sheet, crimped,
folded, shaped, beaded, granulated and mixtures thereof. In most
examples the tobacco portion 2 comprises tobacco although other
botanicals or flavour agents may also be used. In variations of the
examples shown, the tobacco portion 2 may be occupied by a cut
tobacco rod or fully or partially by ground tobacco. Selection of
the material for the tobacco portion 2 is dependent upon a number
of factors such as desired level of flavour delivery and the
requirements to meet an appropriate pressure drop.
[0032] In a preferred embodiment of this invention, the tobacco
derived portion 2 is obtained by carefully selecting a mix of cured
tobacco grades based upon desirable taste attributes and low levels
of undesirable chemicals; reducing the particle size of the plant
material by cutting or grinding to a size suitable for further
processing; treating the tobacco material to further reduce
undesirable components via a suitable combination of processes
including liquid extraction, heat treatment, pressure treatment and
chemical treatment; adding ingredients including humectants to
produce aerosol and flavourants; reconstituting the tobacco into a
sheet format; drying to produce a stable material which is added to
the tobacco article either intact as crimped sheet or as fragments
of cut or shredded sheet. The above steps can be interchanged,
although size reduction is best formed at an early stage in the
process and extraction is preferable before addition of flavours to
minimise losses of the added flavours. Drying is normally the final
stage, although flavour/humectants can be added at the end.
[0033] In some examples a tobacco cut rag is used in the tobacco
portion 2 in which case the density of the tobacco cut rag may be
in the range of 150-500 mg per cm3, preferably in the range 180-280
mg per cm3, and most preferably in the range 200-250 mg per cm3.
Control of this size ensures provision of the maximum possible
tobacco quantity within the volume of the tobacco portion 2 so that
there is maximum transfer into the aerosol.
[0034] In a some examples, the tobacco portion 2 comprises a
flavour material that has been ground or otherwise treated or
formed so that it is in the form of particles, for example, powder,
granules, grains, fibres, beads, pellets or the like so as, for
example, to increase the active surface area or amount of the
flavour material in order to maximise the amount of flavour
imparted to a vapour and/or aerosol stream flowing through the
article.
[0035] As used herein, the terms "flavour" and "flavourant" may
refer to materials which, where local regulations permit, may be
used to create a desired taste or aroma in a product for adult
consumers. They may include extracts (e.g., licorice, hydrangea,
Japanese white bark magnolia leaf, chamomile, fenugreek, clove,
menthol, Japanese mint, aniseed, cinnamon, herb, wintergreen,
cherry, berry, peach, apple, Drambuie, bourbon, scotch, whiskey,
spearmint, peppermint, lavender, cardamom, celery, cascarilla,
nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil,
vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine,
ylang-ylang, sage, fennel, piment, ginger, anise, coriander,
coffee, or a mint oil from any species of the genus Mentha),
flavour enhancers, bitterness receptor site blockers, sensorial
receptor site activators or stimulators, sugars and/or sugar
substitutes (e.g., sucralose, acesulfame potassium, aspartame,
saccharine, cyclamates, lactose, sucrose, glucose, fructose,
sorbitol, or mannitol), and other additives such as charcoal,
chlorophyll, minerals, botanicals, or breath freshening agents.
They may be imitation, synthetic or natural ingredients or blends
thereof. They may be in any suitable form, for example, oil,
liquid, solid, or powder. For example, a liquid, oil, or other such
fluid flavourant may be impregnated in a porous solid material so
as to impart flavour and/or other properties to that porous solid
material. As such, the liquid or oil is a constituent of the
material in which it is impregnated.
[0036] To prevent excessive pressure drop it is preferable to have
the major axis of the tobacco derived sheet running parallel to the
longitudinal axis 6 of the article of the invention to form
pathways for air to pass (see FIG. 2, part 2). In an alternate
preferred embodiment of this invention, the tobacco derived
material is prepared as above except that the tobacco derived
material is reconstituted into a granular or particulate format
which can then be added to the invention.
[0037] Preferably the granular or particulate tobacco derived
material is produced by extrusion, because this ensures consistency
of particle size and shape as well as ensuring uniform distribution
of any added flavourant or humectant.
[0038] In the specific case of the material of the tobacco portion
2 comprising a continuous fibre ground tobacco the tobacco weight
is preferably in the range of 2 mg to 6 mg per mm of the tobacco
portion.
[0039] In the specific case of the material of the tobacco portion
2 comprising short cut fibres ground tobacco the tobacco weight is
preferably in the range of 6 mg to 15 mg per mm of the tobacco
portion 2.
[0040] FIG. 2 shows the longitudinal axis 6 of the article of the
invention, taken as the major axis of the article and running from
the mouth end 3 to the distal end 1. Other axes are taken as
perpendicular to this longitudinal axis. Definition of such axes is
important in the measurement of key physical parameters that
control the integrity of the product during storage & use, and
of the sensory experience that the user receives.
[0041] "Pressure drop" or "draw resistance" is measured using the
Coresta Recommended Method 41.
(https://www.coresta.org/sites/default/files/technical_documents/main/CRM-
_41-update2_0.pdf) and expressed as millimetres water-column
equivalent. This design feature determines how the user can extract
a volume of aerosol from the consumable/device with reasonable
effort.
[0042] "Compressibility" is measured in the longitudinal axis 6 by
application of a fixed force of 10 Newtons at points 5 (see FIG.
2), and measuring the deflection distance as a percentage of the
total product length. Such measurement can be performed using
equipment such as Instron's electromechanical rig 3300.
[0043] In FIG. 1 part 4 shows an "overwrap": one or more sheets of
material that provide the outer surface of the article, act to hold
the separate elements (distal end filter 1, tobacco derived portion
2 and mouth-end filter 3) in sequence relative to each other and
provides structural strength to the article sufficient for required
manipulation by the user, in particular during insertion and
removal from an associated device. An overwrap 4 typically
comprises paper, plastic, foil, laminates or combinations thereof.
An overwrap 4 can comprise a single layer over the entirety of the
article or can have multiple layers at different points as shown in
FIG. 3, parts 8 and 9, as may be required depending on the
underlying construction of the article, for example multi-segment
filter portions are typically held together with an outer wrapper
to assist manufacturing processes. Overwraps of particular
relevance to this invention preferably have grammage in the range
of 20-100 grams per square meter (gsm). A preferred embodiment
utilises a rigid non-porous overwrap in the range of 40-200
g/m.sup.2 composed of transparent cellulose-based paper without
chalk overprinted with metallic inks. The lower limit of the
grammage is usually determined by the need for opacity and physical
strength for the end consumable. The upper limit of the grammage
range is set by the operability of the machinery, which can perform
if the overwrap material is too thick. In terms of the preferred
embodiment, an employment of a rigid non-porous overwrap without
chalk, this had advantages in that printing can be performed on
specific areas to provide shaped windows, logos etc.
[0044] In some examples, the overwrap 4 is configured so that its
acts as a liquid resistant barrier that prevents liquid, for
example, condensation that forms around the article when it is in
use, from getting into the interior of the article and making the
tobacco portion 2 soggy. In one example, a liquid resistance
wrapper layer is used in the overwrap 4 comprises paper impregnated
with a barrier material or Natureflex or other suitable thin
polymer film.
[0045] In a preferred embodiment of the present invention, the
overwrap 4 is supplied as a continuous roll of material which is
bent in the cross-direction, shaped into a continuous cylinder and
affixed to itself using glue. Concurrent with the formation of this
continuous cylinder of overwrap the internal elements, namely
filter portions 1,3 and tobacco derived portions 2, are supplied
and affixed to the overwrap 4 as appropriate. This continuous
cylinder is then cut into the discreet tobacco articles. This
process can be carried out in a continuous manner using a machine
for producing cavity filters as known in the art. In an alternative
preferred embodiment, the continuous roll of overwrap is formed
into a helix and affixed to itself to form the continuous
cylindrical shape with a resultant spiral seam (as seen in FIG. 4).
A helical arrangement has the further advantage that the seam can
provide further structural rigidity to the complete article by
preventing compression in the cross-direction.
[0046] FIGS. 4, 5 and 6 show exemplary embodiments wherein regions
11 are transparent, and regions 12 are opaque. Transparent overwrap
is defined by the ability to allow the user to visually perceive
the contents inside the article. Suitable properties can be found
with transparent, semi-opaque and translucent materials.
Accordingly regions of transparency can be created within an
overwrap 4 by altering the composition of the overwrap 4 in that
region by means including reducing the amount of print, reducing
the amount of an opaque layer, removal of a foil layer or
combinations thereof. A preferred embodiment utilises a transparent
cellulose-based paper opacified with metallic inks to give a
foil-like appearance overall, and has regions with no metallic ink
that serve as transparent windows 11 to view the contents inside
the article. Most preferably these transparent windows 11 are
aligned with the tobacco derived portion 2.
[0047] During storage and use the physical properties of the
overwrap 4 can be affected by absorption of volatile, liquid and
aerosol components. For example, paper based overwraps can absorb
moisture and other liquids which soften the overwrap reducing its
structural integrity; this can be undesirable as it can affect the
user's ability to remove the article from the associated device. It
can also have a detrimental effect upon the visual aesthetics of
the overwrap, for example causing staining. Hence it is desirable
to provide overwraps that resist the absorption and therefore
retain desirable structural properties and appearance. To resist
absorption overwraps can be composed of plastics and foils; have a
plastic or foil inner layer; have an inner surface coated with
varnish or lacquer; be composed of paper with low propensity to
absorb liquids and combinations thereof. These may include
trilaminate foils with a PE:Al:PET type construction. In a
preferred embodiment, the overwrap is transparent cellulose-based
paper without chalk which exhibits a low absorption propensity. An
alternate preferred embodiment the overwrap 4 is a transparent film
of plastic. An alternate preferred embodiment the overwrap 4 is a
paper based material coated with a layer of alkyl ketene dimer
(AKD) on the inner surface.
[0048] Filter portions (FIG. 1, parts 1 and 3) act as a physical
barrier to contain the tobacco-derived portion 2 and maintain the
overall structural integrity of the tobacco article predominantly
in the minor axis whilst allowing the desired air and aerosol to
pass through. In some examples, the material of the filter is
moisture resistant so that the filter portions 1,3 maintain their
shape in use. The mouth-end filter portion 3 can in addition act to
prevent undesirable fine dust particles from the tobacco derived
portion 2 reaching the user and removes aerosol particles larger
than those of an inhalable aerosol.
[0049] The filter portions 1, 3 can each be provided by a filter
portion 21. To enhance airflow through the invention, the pressure
drop of the filter portions 21 (shown in FIG. 9), can be reduced by
the introduction of one or more airflow channels 22 in the
longitudinal axis. Airflow channels 22 can pass the entire length
of the filter portion. Preferably airflow channels 22 pass through
up to 95% of the filter portion length, leaving at least 5% of the
filter portion intact to retain tobacco particles. Airflow channels
22 can be introduced once the filter portion 21 is formed by using
lasers to burn through the filter material or by use of a
mechanical pin to punch the channel 22. Preferably airflow channels
22 are formed by introducing a mandrel or pin into the filter
material during the formation process to shape the channel.
[0050] In some examples, the pressure difference across either of
the portions 1,3 is in the range 0.1 mm to 2 mm water column per mm
length of the section.
[0051] Filter portions 21 typically are composed of cellulose
acetate, paper, plastics, polymers such as polyethylene,
polypropylene or polylactic acid and combinations thereof. In a
preferred embodiment of the present invention the filter portion 21
is composed of cellulose acetate fibres plasticised with up to 15%
triacetin. Filter portions 21 may be homogenous or composed of
multiple contiguous segments. Filter portions 21, and more
preferably the mouth-end filter portion 3, can contain attenuants,
flavourants and aesthetic elements.
[0052] A different additional flavour component may be placed in
each of the end filter portions 1,3 (e.g. a flavour capsule in
distal portion 1 and a flavoured thread or line in the mouth
portion 1).
[0053] In some examples, the filter portions 1,3 comprise a fibrous
material and may be, for example, a fibrous material that is
typically used as a filter material in traditional cigarette,
examples including cellulose acetate fibres, polypropylene fibres,
polyster fibres and paper, including crimped paper. Other materials
may be used for example, nylon and the like.
[0054] In another example, the material of the tobacco portion 2
and the material in the two filter portions 1,3 comprises a
multiplicity of short cut CA fibres (for example fibres cut using a
so called Turmalin apparatus) randomly orientated. Short cut CA
fibres with for example ground tobacco in tobacco portion 2, may
use just enough of the fibres to hold the ground tobacco in a rod
form. Benefits of this arrangement allow for a lower pressure drop
of vapour and/or aerosol flow and additionally there is reduced or
no need for a plasticiser, for example, triacetine to hold the rod
form as is required for a continuous fibre CA. Furthermore, use of
short cut CA fibres enables the use of less CA and more tobacco
than in the case of using a long continuous CA fibre.
[0055] In some examples, the percentage weight of first flavour
component (and any other components e.g. charcoal, plasticiser) in
the filter portions 1,3 to the weight of the material of the
tobacco portion 2 is in the range 10% to 90% and preferably in the
range 70% to 90%.
[0056] In the specific case of the article comprising a continuous
fibre and the tobacco portion 2 comprising ground tobacco the
tobacco weight to the fibre weight is preferably in the range of
40% to 60% and most preferably in the range of 45% to 55%. The
fibre weight is preferably in the range of 75% to 95% and most
preferably in the range of 80% to 90%.
[0057] Attenuants remove undesirable chemicals from the aerosol and
include solid particles of carbon, activated charcoal, carbonaceous
resin derived by pyrolysis, silica, chemically activated
derivatives of carbon and silica, metal based catalysts and
mixtures thereof.
[0058] Flavourants add desirable sensory properties to the aerosol
and can be present in the tobacco-derived portion, the filter
portions and combinations thereof. Common flavourants include
menthol, mint, peppermint, vanilla, liquorice, fruit extracts,
esters, acetals, fructals and combinations thereof. Flavourants can
be present within the filter matrix, the tobacco-derived material,
in a flavour thread, in beads, breakable capsules, non-breakable
capsules, encapsulated within a protective matrix, encapsulated
within a molecule including cyclodextrin and combinations
thereof.
[0059] Aesthetic elements include colourants dispersed within the
filter matrix or localised within a specific region and filters
shaped to form a distinct pattern, logo, or are recessed or fluted
or is combination thereof. This is represented in FIG. 3 which
shows an example filter component providing a mouthend with a
recessed portion 10. In conjunction with the component 7 can
provide a mouth filter portion 3 with the recess 10 in it for use
in the article. This structure provides an aesthetically pleasing
construction that can contribute to product strength by employment
of the layered overwrap 4. It also allows the possibility of
provision of a shorter filter component 7 which can reduce total
pressure drop. With such an example the filter portion 7 will
generally be 6 mm in length or longer to ensure it retains material
in the tobacco portion 2 that still provides appropriate structural
integrity whilst controlling pressure drop and compressibility for
the overall article.
[0060] FIGS. 7 and 8 depict usage of the current invention with an
electronic cigarette as the aerosol-generating device. The device
utilises a battery power source 14 to heat a resistive wire 17 in
order to volatilise an e-liquid from reservoir 16, the liquid is
typically nicotine-free. The article of the invention 19 is
inserted into the electronic-cigarette device at point 18. The
first aerosol produced by resistive wire 17 passes through article
19 and is modified to produce the inhalable aerosol 20. The
modification to the first aerosol includes the addition of nicotine
and other flavourants from the present invention. The modification
can also include the removal of undesirable chemical components via
attenuants and the removal of undesirable aerosol and other
particles from the aerosol.
[0061] In an alternative embodiment, the first aerosol additionally
contains chemicals to assist the incorporation of desirable
chemicals from the tobacco derived portion 2 into the aerosol.
Preferably the first aerosol contains volatile acids which act to
incorporate freebase nicotine from the tobacco derived portion 2
and thereby enhance the amount of nicotine in the inhaled aerosol.
Suitable volatile acids include ascorbic, pyruvic acid and
levulinic acid.
[0062] FIG. 10 shows an alternative use of the current invention,
whereby the current invention is inserted into a device with power
source 14 which uses a heat-source 23 to directly heat the tobacco
portion 2. The action of the heat from the associated device
releases volatile components from the invention which form the
inhalable aerosol. Heat source 23 includes one of electrically
driven or chemical reaction driven heating means. Electrically
driven options include metallic heating elements, resistive wire,
thin film heaters, ceramics heaters and combinations thereof in
conjunction with a battery or cell. Alternatively, an electrically
driven heat-source 23 can rely upon induction, where an alternating
electromagnetic field is produced which in turn generates heat in a
suitably placed susceptor element 24. The efficiency of induction
is improved when the susceptor element 24 is in close proximity to
the material to be heated, therefore the susceptor element 24 is
best placed within the tobacco derived material or as part of the
overwrap in contact with the tobacco derived portion. In the case
of induction heating the power source and circuitry may be
configured to operate at a high frequency. Preferably, the power
source and circuitry may be configured to operate at a frequency of
between approximately 80 kHz and 500 kHz, preferably approximately
150 kHz and 250 kHz, more preferably approximately 200 kHz, and the
assembly may be arranged to operate in use with a fluctuating
electromagnetic field having a magnetic flux density of between
approximately 0.5 Tesla (T) and approximately 2.0 T at the point of
highest concentration. Whilst the induction coil may comprise any
suitable material, typically the induction coil may comprise a Litz
wire or a Litz cable. The susceptor may comprise one or more, but
not limited, of aluminium, iron, nickel, stainless steel and alloys
thereof, e.g. nickel chromium. With the application of an
electromagnetic field in its vicinity, the susceptor may generate
heat due to eddy currents and magnetic hysteresis losses resulting
in a conversion of energy from electromagnetic to heat.
[0063] Chemical reaction driven heat sources include combustion,
oxidation, redox and other exothermic reactions.
[0064] Humectants are additives that act to retain water within a
matrix and include polyols such as propylene glycol, glycerol, PEGs
of various molecular weights, sugar alcohols such as sorbitol and
combinations thereof. Within the present invention volatilised
humectants also function to produce aerosol droplets. Preferably
the humectant is a mixture of propylene glycol and glycerol.
[0065] pH modifying agents include acids, bases and buffers which
can be used to alter the ionisation state of chemicals within the
tobacco derived portion thereby modifying their volatility. Notably
free base nicotine which predominates at alkaline pH is
significantly more volatile than nicotine salts which predominate
at acidic pH. In a preferred embodiment sufficient basic agents are
added to the tobacco derived portion to achieve an overall pH>7
rendering more nicotine available to be volatilised into the
inhalable aerosol. More preferably the overall pH is >8.
Suitable basic agents include metal carbonates, metal hydrogen
carbonates, metal hydroxides and ammonium salts.
[0066] In one embodiment of the present invention the tobacco
derived portion 2 is generated by providing a blend of tobacco
grades comprising flue cured and air-cured tobaccos with a chemical
composition in accordance to Gothiatek.RTM. Standard, namely
tobacco-specific nitrosamine (NNN+NNK) content of <1 mg/kg and
benzo[a]pyrene content of <1.25 ug/kg. Once blended, the tobacco
is reduced in size by first shredding and then grinding to pass
through a No. 18 Mesh giving a particle size of =<1 mm. To the
ground tobacco is added 50% equivalent mass of deionised water; 2%
equivalent mass of flavourant--a 50:50 mix of menthol and mint
oils; 0.375% equivalent mass pH modifying agent--sodium hydroxide.
The resultant tobacco paste is passed through a Coperion extruder
with barrel temperature 250.degree. C. and pressure 4 atm linked to
a pelletizer to produce a shaped material of particle size
approximately 1.5 mm diameter. The tobacco derived particles are
then dried under vacuum to <10% moisture. The dried tobacco
particles are then sieved to produce a fraction in the range 0.2
mm.about.1.25 mm. The mouth end and distal end filter portions 1,3
are manufactured using a Hauni filter rod making machine. Filter
portions 1,3 are made from cellulose acetate tow 6Y17 using 10.1 mg
of tow per mm of filter length; plasticised with 12% weight/weight
triacetin; 26 gsm, 2000 CU plugwrap affixed with PVA glue. Final
filter portion dimensions are 8 mm diameter and 6 mm length. The
assembly of the non-combustible tobacco article is carried out on a
Molins cavity filter machine using a paper overwrap PPW 35 by SWM
with a 0.1% coating of AKD on the inner surface. The construction
of the article is 6 mm filter portion, 17 mm cavity with 250 mg
tobacco-derived material, 6 mm filter portion affixed with PVA
glue. This generates a final article with a total pressure drop of
40-65 mm water column and compressibility factor of .about.3% in
the longitudinal axis.
[0067] With the present invention, by controlling the
compressibility of the article it is possible to provide a device
which is easy for a user to handle and remove from a vapour
generating device without deformation or damage even though the
generation of vapour during use will potentially deteriorate the
mechanical properties of the article. By optionally controlling
draw pressure it is possible to ensure a pressure drop that a user
is comfortable in creating the draw pressure when receiving vapour.
In addition, the invention ensures that an article to hold an
appropriate of vapour generating material can be provided in an
article which is aesthetically pleasing and simple and
straightforward to manufacture.
* * * * *
References