U.S. patent application number 17/423797 was filed with the patent office on 2022-04-14 for tobacco constituent releasing components, methods of making the components and articles comprising the components.
The applicant listed for this patent is BRITISH AMERICAN TOBACCO (INVESTMENTS) LIMITED. Invention is credited to Dietmar FRANKE, Matthias LINK, Frank PLUCKHAHN, Ugurhan YILMAZ.
Application Number | 20220110361 17/423797 |
Document ID | / |
Family ID | 1000006097095 |
Filed Date | 2022-04-14 |
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United States Patent
Application |
20220110361 |
Kind Code |
A1 |
LINK; Matthias ; et
al. |
April 14, 2022 |
TOBACCO CONSTITUENT RELEASING COMPONENTS, METHODS OF MAKING THE
COMPONENTS AND ARTICLES COMPRISING THE COMPONENTS
Abstract
Tobacco constituent releasing components comprising an
agglomerated structure formed from a precursor composition
comprising tobacco particles and one or more aerosol forming
agents, processes for preparing tobacco constituent releasing
components, and various tobacco industry products including the
tobacco constituent releasing components.
Inventors: |
LINK; Matthias; (London,
GB) ; YILMAZ; Ugurhan; (London, GB) ; FRANKE;
Dietmar; (London, GB) ; PLUCKHAHN; Frank;
(London, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BRITISH AMERICAN TOBACCO (INVESTMENTS) LIMITED |
London |
|
GB |
|
|
Family ID: |
1000006097095 |
Appl. No.: |
17/423797 |
Filed: |
January 16, 2020 |
PCT Filed: |
January 16, 2020 |
PCT NO: |
PCT/GB2020/050085 |
371 Date: |
July 16, 2021 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24D 1/20 20200101; A24B
3/14 20130101; A24C 5/01 20200101; A24D 3/048 20130101; A24B 15/167
20161101 |
International
Class: |
A24D 1/20 20060101
A24D001/20; A24B 15/167 20060101 A24B015/167; A24B 3/14 20060101
A24B003/14; A24D 3/04 20060101 A24D003/04; A24C 5/01 20060101
A24C005/01 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 16, 2019 |
GB |
1900627.9 |
Claims
1. A tobacco constituent releasing component comprising: an
agglomerated structure formed from a precursor composition
comprising tobacco particles and optionally one or more aerosol
forming agents; wherein the tobacco particles comprising one or
more tobacco constituents; and wherein the release of the one or
more tobacco constituents upon heating the component without
combustion being controlled by adjusting one or more of: (i) a
ratio of the surface area to volume of the component, and (ii) an
amount of the optional one or more aerosol forming agents
included.
2. A tobacco constituent releasing component as claimed in claim 1,
wherein the one or more aerosol forming agents is included in an
amount of from about 3% to about 30% by weight of the
component.
3. A tobacco constituent releasing component as claimed in claim 1,
wherein the one or more aerosol forming agents is included in an
amount of at least 10% by weight of the component, wherein the
tobacco constituent releasing component having one or more
undulating or irregular surfaces and/or channels within the
component, and wherein the tobacco within the component does not
have a basic pH.
4. A tobacco constituent releasing component as claimed in claim 1,
further comprising one or more inner channels extending through the
component.
5. A tobacco constituent releasing component as claimed in claim 1,
wherein the component has a cross-sectional shape of a spoked wheel
or a star.
6. A tobacco constituent releasing component as claimed in claim 1,
wherein the agglomerated structure is formed by extrusion.
7. A tobacco constituent releasing component as claimed in claim 1,
wherein the one or more aerosol forming agents is selected from the
group consisting of glycerol, propylene glycol and glyceryl
triacetate.
8. A tobacco constituent releasing component as claimed in claim 1,
wherein the component is impregnated with the one or more aerosol
forming agents, and/or the tobacco particles are impregnated with
the one or more aerosol forming agents.
9. A tobacco constituent releasing component as claimed in claim 1,
comprising at least 50% by weight tobacco particles.
10. A tobacco constituent releasing component as claimed in claim
1, comprising at least 80% by weight a combination of tobacco
particles and one or more aerosol forming agents.
11. A tobacco constituent releasing component as claimed in claim
1, wherein the tobacco particles have an average diameter no
greater than 0.5 mm.
12. A tobacco constituent releasing component as claimed in claim
1, wherein the component having a generally rod-shaped external
form.
13. A tobacco constituent releasing component as claimed in claim
1, wherein the component having a diameter of from about 4 mm to
about 10 mm.
14. A tobacco constituent releasing component as claimed in claim
1, wherein the component having a length of from about 5 mm to
about 80 mm.
15. A tobacco constituent releasing component as claimed in claim
1, wherein the component does not have a basic pH and/or the
precursor composition does not have a basic pH.
16. A tobacco constituent releasing component as claimed in claim
1, wherein the precursor composition does not include a basic pH
adjusting agent.
17. A tobacco constituent releasing component as claimed in claim
1, further comprising one or more binders selected from the group
consisting of starches, polysaccharides, pectins, celluloses,
cellulose derivatives, carboxymethylcellulose, and alginates.
18. A tobacco constituent releasing component as claimed in claim
1, wherein the component does not comprise a binder to assist
agglomeration of the tobacco particles.
19. A tobacco constituent releasing component as claimed in claim
1, the tobacco constituent releasing component further comprising
one or more flavor-modifying additives.
20. A process for preparing a tobacco constituent releasing
component, comprising: forming an agglomerated structure from a
precursor composition comprising tobacco particles and optionally
at least one aerosol forming agent, wherein the tobacco particles
comprising one or more tobacco constituents; wherein a desired
release of the one or more tobacco constituents is provided upon
heating the component without combustion by adjusting one or more
of: (i) a ratio of the surface area to volume of the component, and
(ii) an amount of the optional at least one aerosol forming agent
included.
21. (canceled)
22. A process as claimed in claim 20, wherein the precursor
composition is extruded to form the agglomerated structure, wherein
the precursor composition comprises at least 10% by weight of the
at least one aerosol forming agent, wherein the extruded tobacco
constituent releasing component having one or more undulating or
irregular surfaces and/or channels within the component, and
wherein the process does not include adjusting the pH of the
tobacco within the component to a basic pH.
23. A process as claimed in claim 20, wherein the precursor
composition is extruded to form the agglomerated structure.
24. A process as claimed in claim 23, wherein the precursor
composition is extruded through a die to provide one or more inner
channels extending through the component.
25. A process as claimed in claim 23, wherein the precursor
composition is extruded through a die to provide the component with
a cross-sectional shape of a spoked wheel or a star.
26. A process as claimed in claim 23, wherein the precursor
composition is heated to a temperature of from about 40.degree. C.
to about 120.degree. C.
27. A process as claimed in claim 23, wherein the precursor
composition is cooled during or after extrusion by exposure to a
surface having a temperature of from about 5.degree. C. to about
15.degree. C.
28. A process as claimed in claim 20, wherein the pH of the
component and/or of the precursor composition is not adjusted to a
basic pH.
29. A process as claimed in claim 20, wherein the precursor
composition does not include a basic pH adjusting agent.
30-36. (canceled)
37. A filter or filter element for a combustible smoking article
comprising a tobacco constituent releasing component of claim 1,
wherein the tobacco constituent releasing component delivering
flavor to mainstream smoke upon use of the smoking article, and
wherein the pH of the component and/or of the precursor composition
is not adjusted to a basic pH.
38-42. (canceled)
Description
[0001] The present application is a National Phase entry of PCT
Application No. PCT/GB2020/050085, filed Jan. 16, 2020 which claims
priority from GB Patent Application No. 1900627.9 filed Jan. 16,
2019, each of which is hereby fully incorporated herein by
reference.
TECHNICAL FIELD
[0002] The present disclosure relates to tobacco constituent
releasing components comprising tobacco particles in an
agglomerated structure. The disclosure also relates to tobacco
industry products including the tobacco constituent releasing
components and to methods of manufacturing the tobacco constituent
releasing components.
BACKGROUND
[0003] It is known to provide a source of tobacco constituents from
which said tobacco constituents are released upon heating the
source without combustion. Drawbacks associated with such sources
can include, for example, inadequate control of the release of the
tobacco constituents, and only a relatively small proportion of the
constituents being released during the normal use of the
product.
SUMMARY
[0004] According to a first aspect of the disclosure, a tobacco
constituent releasing component is provided, comprising an
agglomerated structure formed from a precursor composition
comprising tobacco particles, the release of the tobacco
constituents upon heating the component without combustion being
controlled by adjusting one or more of: (i) the surface area to
volume ratio of the component; and (ii) the amount of aerosol
forming agent(s) included.
[0005] In some embodiments, the one or more aerosol forming agent
is included in an amount of from about 3% to about 30% by weight of
the component, preferably in an amount of from about 15% to about
30% by weight of the component.
[0006] According to a second aspect of the disclosure, a tobacco
constituent releasing component is provided comprising an
agglomerated structure formed from a precursor composition
comprising tobacco particles and at least 10% by weight of at least
one aerosol forming agent, the tobacco constituent releasing
component having one or more undulating or irregular surfaces
and/or channels within the component, and wherein the tobacco
within the component does not have a basic pH.
[0007] In some embodiments, the tobacco constituent releasing
component has one or more inner channels extending through the
component.
[0008] In some embodiments, the tobacco constituent releasing
component has a cross-sectional shape of a spoked wheel or a
star.
[0009] In some embodiments, the agglomerated structure is formed by
extrusion.
[0010] In some embodiments, the aerosol forming agent is one or
more selected from the group consisting of glycerol, propylene
glycol and glyceryl triacetate.
[0011] In some embodiments, the tobacco constituent releasing
component is impregnated with one or more aerosol forming agents,
and/or the tobacco particles are impregnated with the one or more
aerosol forming agents.
[0012] In some embodiments, the tobacco constituent releasing
component comprises at least 50% by weight tobacco particles.
[0013] In some embodiments, the tobacco constituent releasing
component comprises at least 80% by weight a combination of tobacco
particles and aerosol forming agent.
[0014] In some embodiments, the tobacco particles have an average
diameter no greater than 0.5 mm and preferably wherein the tobacco
particles have an average particle size within the range of about
0.1 to about 0.4 mm.
[0015] In some embodiments, the tobacco constituent releasing
component has a generally rod-shaped external form.
[0016] In some embodiments, the tobacco constituent releasing
component has a diameter of from about 4 mm to about 10 mm, and
preferably from about 5 mm to about 8 mm.
[0017] In some embodiments, the tobacco constituent releasing
component has a length of from about 5 mm to about 80 mm, and
preferably from about 10 mm to about 25 mm.
[0018] In some embodiments, the tobacco constituent releasing
component does not have a basic pH and/or the precursor composition
does not have a basic pH.
[0019] In some embodiments, the precursor composition does not
include a basic pH adjusting agent.
[0020] In some embodiments, the tobacco constituent releasing
component further comprises one or more binders, preferably wherein
the one or more binders are selected from the group consisting of:
starches, polysaccharides, pectins, celluloses, cellulose
derivatives such as carboxymethylcellulose, and alginates.
[0021] In some embodiments, the tobacco constituent releasing
component does not comprise a binder to assist agglomeration of the
tobacco particles.
[0022] In some embodiments, the tobacco constituent releasing
component further comprises one or more flavor-modifying
additive.
[0023] According to a third aspect of the disclosure, a process for
preparing a tobacco constituent releasing component is provided,
comprising forming an agglomerated structure from a precursor
composition comprising tobacco particles, wherein a desired release
of the tobacco constituents is provided upon heating the component
without combustion by adjusting one or more of: (i) the surface
area to volume ratio of the component; and (ii) the amount of
aerosol forming agent(s) included.
[0024] In some embodiments, the process is for preparing a tobacco
constituent releasing component according to the first aspect.
[0025] According to a fourth aspect of the disclosure, a process
for preparing a tobacco constituent releasing component is
provided, comprising forming by extrusion an agglomerated structure
from a precursor composition comprising tobacco particles and at
least 10% by weight of at least one aerosol forming agent, the
extruded tobacco constituent releasing component having one or more
undulating or irregular surfaces and/or channels within the
component, and wherein the process does not include adjusting the
pH of the tobacco within the component to a basic pH.
[0026] In some embodiments of the processes, the precursor
composition is extruded to form the agglomerated structure.
[0027] In some embodiments of the processes, the precursor
composition is extruded through a die to provide one or more inner
channels extending through the component.
[0028] In some embodiments of the processes, the precursor
composition is extruded through a die to provide the component with
a cross-sectional shape of a spoked wheel or a star.
[0029] In some embodiments of the processes, the precursor
composition is heated to a temperature of from about 40.degree. C.
to about 120.degree. C.
[0030] In some embodiments of the processes, the precursor
composition is cooled during or after extrusion, preferably wherein
the precursor composition is cooled by exposure to a surface having
a temperature of from about 5.degree. C. to about 15.degree. C.
[0031] In some embodiments of the processes, the pH of the
component and/or of the precursor composition is not adjusted to a
basic pH.
[0032] In some embodiments of the processes, the precursor
composition does not include a basic pH adjusting agent.
[0033] According to a fifth aspect of the disclosure, there is
provided, in the preparation of a tobacco constituent releasing
component having an agglomerated structure formed from a precursor
composition comprising tobacco particles and one or more aerosol
forming agents, the use of a step of selecting one or more of: (i)
the surface area to volume ratio of the component; and (ii) the
amount of aerosol forming agent(s) included, to provide the tobacco
constituent releasing component with a desired release of the
tobacco constituents upon heating the component without
combustion.
[0034] In some embodiments, the use is for preparing a tobacco
constituent releasing component according to the first aspect.
[0035] In some embodiments of the use, the surface area to volume
ratio of the component is increased by forming the agglomerated
structure to provide one or more inner channels extending through
the component.
[0036] In some embodiments of the use, the component has a
cross-sectional shape of a spoked wheel or a star.
[0037] In some embodiments of the use, the pH of the component
and/or of the precursor composition is not adjusted to a basic
pH.
[0038] In some embodiments of the use, the precursor composition
does not include a basic pH adjusting agent.
[0039] According to a sixth aspect of the disclosure, a smoking
article comprising a filter and a rod of smokeable material is
provided, the filter comprising a tobacco constituent releasing
component according to the first aspect.
[0040] According to a seventh aspect of the disclosure, a filter or
filter element for a combustible smoking article is provided,
comprising a tobacco constituent releasing component, the tobacco
constituent releasing component comprising an agglomerated
structure formed by extruding a precursor composition comprising
tobacco particles, the tobacco constituent releasing component
delivering flavor to mainstream smoke upon use of the smoking
article, wherein the pH of the component and/or of the precursor
composition is not adjusted to a basic pH.
[0041] In some embodiments, the filter or filter element for a
combustible smoking article comprises a tobacco constituent
releasing component according to the first aspect.
[0042] According to an eighth aspect of the disclosure, an
apparatus for heating smokeable material without combustion to
volatilize at least one component of the smokeable material is
provided, the smokeable material comprising one or more tobacco
constituent releasing components according to the first aspect.
[0043] In some embodiments, the apparatus further comprises liquid
which is to be heated to form a vapor, optionally wherein the
liquid does not comprise nicotine.
[0044] In some embodiments of the apparatus, the smokeable material
is heated by the vapor.
[0045] In some embodiments of the apparatus, a means for heating
the liquid to form a vapor is included, but a separate means for
heating the smokeable material is not included.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] Embodiments of the disclosure will now be described, by way
of example only, with reference to accompanying drawings, in
which:
[0047] FIG. 1 is a flow chart showing key steps of a process
according to certain embodiments of the present disclosure;
[0048] FIGS. 2a, 2b and 2c show examples of nozzle designs for
forming extruded agglomerates having inner channels, while FIGS. 2d
and 2e show how such a die may be used to shape the extruded
agglomerate;
[0049] FIG. 3 shows a series of extruded agglomerates, showing
different cross-sectional geometries forming inner channels;
[0050] FIG. 4a shows an example of a die used to produce granules
by extrusion, while FIG. 4b shows how such a die may be used to
form the extruded agglomerates;
[0051] FIG. 5 is a schematic representation of some extruded
granules;
[0052] FIG. 6 is a schematic cross-sectional view of a tobacco
heating product for heating smokeable material to volatilize at
least one component of the smokeable material including a tobacco
constituent releasing component;
[0053] FIG. 7 is a schematic view of a Hybrid device for heating
smokeable material to volatilize at least one component of the
smokeable material including a tobacco constituent releasing
component;
[0054] FIG. 8 is a schematic cross-sectional view of an example of
a cartridge containing multiple tobacco constituent releasing
components;
[0055] FIG. 9 is a schematic side view of a combustible smoking
article including a filter comprising multiple tobacco constituent
releasing components;
[0056] FIG. 10 is a schematic side view of a combustible smoking
article including a filter comprising a single tobacco constituent
releasing component; and
[0057] FIG. 11 is a schematic side view of a combustible smoking
article including a multi-segment filter wherein one filter segment
is a tobacco constituent releasing component.
DETAILED DESCRIPTION
[0058] The disclosure relates to tobacco constituent releasing
components that are formed from tobacco particles. These components
are able to release tobacco constituents including flavors and
nicotine. They may also act as a carrier for other materials that
are to be released. The tobacco constituent releasing components
are suitable for incorporation into various tobacco industry
products.
[0059] At least some of the released constituents are directly
derived from the tobacco particles used to form the components. In
some embodiments, further materials may be added to the components
for release. These further materials may, for example, also
comprise tobacco constituents added to supplement those directly
derived from the tobacco particles. Alternatively or in addition,
the further materials added to the components for release may not
be derived from tobacco. For example, the components may also, in
some embodiments, carry and release other flavors, including those
not derived from tobacco.
[0060] Incorporated into a tobacco industry product, the tobacco
constituent releasing component is able to modify the aerosol
produced by said product during use. The flow of air or aerosol
over and/or through the component, optionally with heating, causes
the release of materials from the component. The released materials
may, in some embodiments, include tobacco constituents such as
flavors and aromas, as well as other tobacco derived materials such
as nicotine, and, where included in the tobacco constituent
releasing component, materials that are not derived from tobacco or
are not derived from the tobacco particles included in the
components.
[0061] The released materials become entrained in the air or
aerosol, modifying it. In some embodiments, the flavor, aroma or
taste of the aerosol produced by the tobacco industry product is
modified by the tobacco constituent releasing component. In some
embodiments, the aerosol is enriched with natural tobacco flavors
and aromas. Additionally or alternatively, the aerosol is modified
with non-tobacco flavors as a result of flavors or flavor sources
being incorporated into the tobacco constituent releasing
components. In further embodiments, the aerosol may be modified by
the addition of nicotine. In yet further embodiments, the mouthfeel
of the aerosol may be modified by materials, such as aerosol
forming agents, released by the tobacco component releasing
components.
[0062] The tobacco constituent releasing components are
agglomerated structures formed from a precursor composition
comprising tobacco particles. This means that the components are a
mass or cluster formed by fusing or adhering multiple particles to
one another. The constituent particles include tobacco particles.
In some embodiments, particles of other materials may also be
included.
[0063] An important aspect of the disclosure is that the release of
materials from the tobacco constituent releasing components may be
controlled and adapted to the specific requirements of the tobacco
industry product into which it is to be incorporated. In
particular, it is desirable to control the rate and extent of
release. The release of materials is key for providing the desired
flavor profile during use of the tobacco industry product, as well
as the desired sensorial experience. In particular, it may be
desirable to control how quickly the release occurs following
commencement of the use of the product, the longevity of release
and the consistency of release. It is also important to ensure that
a significant proportion of the materials to be released contained
in the tobacco constituent releasing component is actually released
during the normal use of the tobacco industry product.
[0064] A tobacco constituent releasing component is provided,
comprising an agglomerated structure formed from a precursor
composition comprising tobacco particles, the release of the
tobacco constituents upon heating the component without combustion
being controlled by adjusting one or more of: (i) the surface area
to volume ratio of the component; and (ii) the amount of aerosol
forming agent(s) included.
[0065] In order to improve release of the tobacco constituents and
other materials from the component during use in a tobacco industry
product (where the component is heated but not combusted), it is
desirable for the component to have a high surface area to volume
ratio. An increased surface area of the tobacco constituent
releasing component will increase the release of the tobacco
constituents and other materials. The increased surface area to
volume ratio means that more of the tobacco constituents and other
materials will be situated closer to the surface of the component,
so that they are heated and released more readily, and a greater
proportion is released. As used herein, an increased surface area
or an increased surface area to volume ratio refers to in a
comparison with the surface area of a solid structure which is
roughly spheroid or has a cylindrical rod shape or the same
volume.
[0066] As described in greater detail below, the shape of the
tobacco constituent releasing components may be selected to
increase the surface area to volume ratio, for example by
increasing the surface area by creating undulating or irregular
surfaces or by creating channels within the components. It is
desirable to reduce the distance from the surface of the component
of the tobacco constituents and other materials to be released, so
that as much of these materials may be released during use of the
tobacco industry product, rather than remaining trapped within the
agglomerated structure. Increased proximity of the tobacco
constituents and other materials to the surface of the tobacco
constituent releasing component will also mean that the materials
can be released in a controlled manner as they will be more readily
heated and volatilize when the component is heated.
[0067] The surface area of the tobacco constituent releasing
component, and thus the release of the tobacco constituents and
other materials, may also be increased by the presence of pores
within the agglomerated structure. Such pores will reduce the
density of the agglomerated structure, enhancing thermal transfer
throughout the tobacco constituent releasing component. In some
embodiments, pores may be formed by including porous materials in
the precursor composition. Selecting larger diameter tobacco
particles and/or tobacco particles with a narrow particle size
distribution can also enhance the formation of small gaps or pores
within the agglomerated structure. Alternatively or in addition,
pores may be formed in the agglomerated structure after the
agglomerated structure has been made from the precursor
composition, for example by puncturing the structure or by
selectively removing part or parts of the agglomerated
structure.
[0068] Thus, a combination of the shape of the tobacco constituent
releasing component and the porosity/density may be selected to
control the surface area to volume ratio and/or to control: (i) the
heat transfer rate; (ii) the aerosol production rate; (iii) the
amount of aerosol produced; and (iv) the extent of the release of
the tobacco constituents and other materials.
[0069] The tobacco constituent releasing components according to
the disclosure include at least one aerosol forming agent. It is
known to use aerosol forming agents to improve the mouthfeel of
aerosols. The amount of aerosol forming agent that is included in
tobacco components or materials, such as those included in tobacco
heating products, tends to be limited as the aerosol forming agents
are generally in liquid form and are present on the surface of the
tobacco material they are added to. As a result, in practice the
inclusion of more than about 10% by weight of the aerosol forming
agent renders the material difficult to handle and process.
[0070] However, as discussed in greater detail below, embodiments
of the present disclosure allow greater amounts of aerosol forming
agent to be included. This provides greater flexibility in
selecting the amount of aerosol forming agent and this may be used
to control or adjust the release of tobacco constituents and other
materials from the tobacco constituent releasing components.
Release of the aerosol forming agent in the form of an aerosol as a
result of the heating (but not combustion) of the tobacco
constituent releasing component not only improves the properties of
the aerosol generated by the tobacco industry product the component
is incorporated into, but also enhances the release of tobacco
constituents and other materials from the component. This is
particularly the case where the tobacco and/or the agglomerated
structure is impregnated with the aerosol forming agent.
[0071] The amount of aerosol forming agent will also influence the
rate at which the aerosol is generated.
[0072] The aerosol forming agent may be, for instance, a polyol
aerosol generator or a non-polyol aerosol generator, preferably a
non-polyol aerosol generator. It may be a solid or liquid at room
temperature, but preferably is a liquid at room temperature.
Suitable polyols include sorbitol, glycerol, and glycols like
propylene glycol or triethylene glycol. Suitable non-polyols
include monohydric alcohols, high boiling point hydrocarbons, acids
such as lactic acid, and esters such as diacetin, triacetin,
triethyl citrate or isopropyl myristate. A combination of aerosol
forming agents may be used, in equal or differing proportions.
Glycerol, propylene glycol and glyceryl triacetate (also known as
triacetin) are particularly preferred.
[0073] In this disclosure, the release of the tobacco constituents
or other materials is not controlled by adjusting the pH of the
tobacco and/or the precursor composition or of the tobacco
constituent releasing component. Such pH adjustment can change the
nature of the constituents and may be undesirable or unacceptable
from a regulatory standpoint for some products in some
jurisdictions.
Tobacco Particles
[0074] The tobacco particles present in the precursor composition
have a size small enough to ensure that multiple such particles can
be agglomerated to form tobacco constituent releasing components
having desired dimensions based upon their intended use. Smaller
tobacco particles have a greater surface area to volume ratio and
they may therefore exhibit enhanced release of tobacco constituents
compared to particles of larger sizes.
[0075] In addition, the size of the tobacco particles (and of other
particles in the precursor composition) will have an effect on the
porosity and density of the agglomerated structures and tobacco
constituent releasing components. Thus, the size of the tobacco
particles may be selected to produce a more porous agglomerated
structure, which will have an impact on the release of the tobacco
constituents. Thus, the size of the tobacco particles is another
factor that may be adjusted in order to influence the release of
tobacco constituents.
[0076] The extrusion processes used to form the agglomerated
structures can be sensitive to the size of the particles within the
composition being extruded. Therefore, it may be desirable for the
particles in the precursor composition, including the tobacco
particles, to have an average particle size of no greater than
about 0.5 mm, or to have an average particle size of no greater
than about 0.3 mm, when measured by sieving. In some embodiments,
it may be desirable for the tobacco particles in the precursor
composition to have an average particle size of no greater than
about 0.5 mm, or to have an average particle size of no greater
than about 0.3 mm, when measured by sieving. In some embodiments,
the average particle size is within the range of about 0.1 to about
0.4 mm, or in the range of about 0.2 to about 0.3 mm. In some
embodiments, at least about 90% of the particles of the precursor
composition will have a particle size within the range of 0.1 to
0.5 mm. In some embodiments, at least about 90% of the tobacco
particles of the precursor composition will have a particle size
within the range of 0.1 to 0.5 mm. In some embodiments, none of the
particles in the precursor composition have a particle size greater
than 1 mm.
[0077] Tobacco particles for inclusion in the tobacco constituent
releasing components may be formed by grinding, shredding, cutting
or crushing tobacco material. Suitable machinery to create such
tobacco particles includes, for example, shredders, cutters, or
mills, such as hammer mills, roller mills or other types of
commercially available milling machinery.
[0078] Without wishing to be bound by any one particular theory, it
is speculated that the chopping of the tobacco to form the tobacco
particles enhances the release of tobacco constituents including
volatile flavors and aromatic constituents, as well as nicotine.
The increased surface area of the tobacco particles is also thought
to aid volatilization. The smaller tobacco particles also improve
the homogeneity of agglomerated structures formed therefrom
together with other components.
[0079] The tobacco material used to form the tobacco particles may
be any type of tobacco and any part of the tobacco plant, including
tobacco lamina, stem, stalk, ribs, scraps and shorts or mixtures of
two or more thereof. Suitable tobacco materials include the
following types: Virginia or flue-cured tobacco, Burley tobacco,
Oriental tobacco, or blends of tobacco materials, optionally
including those listed here. The tobacco may be expanded, such as
dry-ice expanded tobacco (DIET), or processed by any other means.
In some embodiments, the tobacco material may be reconstituted
tobacco material. The tobacco may be pre-processed or unprocessed,
and may be, for instance, solid stems (SS); shredded dried stems
(SDS); steam treated stems (STS); or any combination thereof. The
tobacco material may be fermented, cured, uncured, toasted, or
otherwise pre-treated.
Additional Components of Precursor Composition
[0080] In some embodiments, the precursor composition comprises a
diluent. The diluent may be in solid or liquid form. In some
embodiments, the diluent is inert or substantially inert.
[0081] In some embodiments, the agglomerated structure formed from
the precursor composition may have an increased surface area by
including in the precursor composition particles of an inert filler
material. Suitable inert fillers may be porous or non-porous.
[0082] In some embodiments, the precursor composition does not
include a binder or binding additive. In other embodiments, the
precursor composition comprises a binder or binding additive. The
binding additive may be selected to assist in the formation of an
agglomerated structure by helping to adhere the tobacco particles
to each other and to other components in the composition. Suitable
binding additives include, for example, starches, polysaccharides,
pectins, celluloses, cellulose derivatives such as
carboxymethylcellulose, and alginates.
[0083] In some embodiments, the tobacco constituent releasing
components may include a flavor-modifier, to modify the flavor
provided by the tobacco particles or to add flavor. In some
embodiments, the flavor-modifier--modifier may be included in the
precursor composition. Alternatively or in addition, the
flavor-modifier may be added to or applied to the agglomerated
structure. Flavor-modifiers include, for example, casing materials,
as well as "flavor" and "flavorant" materials which, where local
regulations permit, may be used to create a desired taste or aroma
in a product for adult consumers.
[0084] 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, cardamon, 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), flavor
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, gel, wax or
powder.
[0085] In some embodiments, the pH of the tobacco of the tobacco
constituent releasing components is not adjusted. In particular, in
some embodiments, the component does not have a basic pH and/or the
precursor composition does not have a basic pH. Additionally or
alternatively, the precursor composition preferably does not
include a basic pH adjusting agent.
[0086] In some embodiments, water may be added to the precursor
composition as a processing aid. For example, the presence of water
may help to dissolve components of the precursor composition,
and/or it may assist with binding or improve agglomeration.
Forming the Agglomerated Structures
[0087] FIG. 1 is a flow chart showing the key steps in the
processes of the present disclosure. The tobacco starting material,
which may be pre-treated or pre-processed, is provided in the form
of particles having the desired particle size. The tobacco
precursor composition is formed, comprising the tobacco particles,
at least one aerosol forming agent and, in some embodiments, may
include further additional components. These additional components
may be in liquid form or in solid form. Additional solid components
are preferably in particulate or powder form. In other embodiments,
the additional components may be introduced into the agglomerated
structure separate from the tobacco precursor composition.
[0088] In some embodiments, water may be added to the precursor
composition as a processing aid. For example, the presence of water
may help to dissolve components of the precursor composition,
and/or it may assist with binding or improve agglomeration.
[0089] Finally, the precursor composition is formed into an
agglomerated structure, i.e., a monolithic structure formed from
multiple tobacco particles and the other components of the
precursor composition. In some embodiments, the agglomerated
structure may be formed from the precursor composition by a process
including one or more steps selected from the group consisting of
granulation and/or extrusion, and optionally also
spheronisation.
[0090] Granulation of the precursor composition involves the
binding or fusing together of the particles of the precursor
composition to form larger, multi-particle entities which are
referred to herein as agglomerated structures. The multi-particle
entities formed by granulation are called granules and they may
have various geometric shapes, including, for example, the general
form of spheres, cylinders, and the like.
[0091] In one embodiment, the granulation step used is wet
granulation. In wet granulation, granules are formed by the
addition of a granulation liquid onto a powder bed. Agitation in
the system, along with the wetting of the components within the
precursor composition, results in the aggregation of the particles
to produce wet granules. The granulation liquid may be at least
partially removed by drying to provide dry granules. The
granulation liquid may be water-based or solvent-based. Suitable
granulation liquids include, for example, water, glycerol, ethanol
and isopropanol, either alone or in combination. In some
embodiments, the granulation liquid comprises an aerosol forming
agent, such as glycerol or one of the other agents mentioned
herein, and/or a binder or binding agent. In some embodiments, no
water is added to the precursor composition to aid granulation.
[0092] In another embodiment, the granulation step used is dry
granulation. In dry granulation, granules are formed without using
a granulation liquid. This type of process has the advantage that
it does not expose the precursor composition to moisture and so
there is no requirement to expose the granules to heat in order to
dry them. Forming granules by dry granulation involves compacting
and densifying the precursor composition, usually under high
pressure.
[0093] Extrusion of the precursor composition involves the feeding
of the precursor composition through an orifice to produce an
extruded agglomerate. The process, which applies pressure to the
precursor composition combined with shear forces, results in
agglomerated structures.
[0094] Extrusion may be performed using one of the main classes of
extruders: screw, sieve and basket, roll, and ram extruders.
Forming the tobacco constituent releasing components by extrusion
has the advantage that this processing combines mixing,
conditioning, homogenizing and molding of the precursor
composition.
[0095] In some embodiments, during extrusion the free-flowing
precursor composition is exposed to elevated pressure and
temperature and is forced though an orifice, such as a shaping die,
to form an extruded agglomerate. In some embodiments, the extruded
agglomerate has an elongated form and/or it may be cut into
segments of a desired length as it exits the orifice. A rod-like
extruded agglomerate may subsequently be cut into segments of
desired length.
[0096] In some embodiments, the precursor composition comprising
tobacco particles is exposed to temperatures from about 40.degree.
C. to about 150.degree. C., or from about 80.degree. C. to about
130.degree. C. within the extruder. The composition may be exposed
to pressures ranging from about 2 bar to about 100 bar, or from
about 5 bar to about 60 bar, depending on the design of the die
being used.
[0097] In some embodiments, due to the relatively high density of
the extruded agglomerate and the relatively open surface of the
tobacco particles within it, the tobacco constituent releasing
components formed from the extruded agglomerate exhibit good heat
transfer and mass transfer, which has a positive impact on the
release of tobacco constituents, such as flavors and nicotine.
[0098] In some embodiments, the extrusion may be a generally dry
process, with the precursor composition being a substantially dry
material that includes tobacco particles, as well as optionally
other particulate materials including, for example, base, diluent,
solid flavor modifiers, etc.
[0099] In some embodiments, liquids may be added to the precursor
composition during the extrusion process. For example, water may be
added to the precursor composition, for example as a processing aid
to assist dissolution or solubilisation of components of the
composition, or to aid binding or agglomeration. Alternatively or
additionally, a wetting agent may be added to the precursor
composition.
[0100] In some embodiments, the liquid may be an aerosol forming
agent such as glycerol or others discussed herein. When liquid is
added to the precursor composition in this manner, the liquid is
applied not only on the surface, but, as a result of the extruder
pressure combined with the intensive mixing by high shear forces,
the extruded agglomerate becomes impregnated with the liquid. Where
the liquid is an aerosol forming agent, this can result in a high
availability of the aerosol forming agent in the agglomerated
product to enhance evaporation of flavor components from the
tobacco particles and other components of the agglomerated
structure, enhancing release of tobacco constituents from the
resultant extruded tobacco constituent releasing components.
[0101] In some embodiments, in view of the impregnation of the
extruded agglomerate with the aerosol forming agent, greater
volumes of this agent can be incorporated into the tobacco
constituent releasing component than if the aerosol forming agent
were simply being applied to the surface of the precursor
composition or of the extruded agglomerate. In some embodiments,
the amount of aerosol forming agent incorporated into the tobacco
constituent releasing component may be at least about 3% by weight,
at least about 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%,
15%, 16%, 17%, 18%, 19% by weight, or at least about 20% by weight.
In some embodiments, the amount of aerosol forming agent
incorporated into the tobacco constituent releasing component may
be up to about 15%, up to about 16%, 17%, 18%, 19%, 20%, 21%, 22%,
23%, 24%, 25%, 26%, 27%, 28%, 29% by weight or up to about 30% by
weight.
[0102] In some embodiments, the one or more aerosol forming agent
is included in an amount of from about 3% to about 30% by weight of
the component, preferably in an amount of from about 15% to about
30% by weight of the component.
[0103] The extruded agglomerate will be shaped by the orifice or
die through which it is forced. In some embodiments, the extruded
agglomerate is cut into pieces of desired length. The pieces formed
in this way may be used as tobacco constituent releasing components
or they may undergo further processing.
[0104] In some embodiments, the orifice or die is shaped to provide
a solid strand of extruded agglomerate. For example, the extruded
agglomerate may have the form of a solid cylindrical rod.
Alternatively, the extruded agglomerate may have different
cross-sectional shapes, including oval, polygonal (such as
triangular, square, etc.), and stars.
[0105] In some embodiments, the extruded composition is formed into
a desired shape selected to enhance or promote the release of
flavor, for example by providing a form having a large surface area
per unit volume. This large surface area may be provided on the
outer surface of the extruded agglomerate, for example by selecting
cross-sectional shapes with large perimeter. Alternatively or in
addition, the large surface area may be provided through the
creation of channels within the extruded agglomerate.
[0106] In some embodiments, the orifice or die is shaped to provide
an extruded agglomerate with inner channels. These inner channels
provide further surface area and can enhance tobacco constituent
release.
[0107] Examples of some nozzle or die designs are shown in FIGS.
2a, 2b and 2c. These nozzles or dies have orifices 21 through which
the extruded composition is forced to produce an extruded
agglomerate with a cartwheel-like spoked structure. These nozzles
or dies are used in an extruder, as shown in FIGS. 2d and 2e, in
which the direction of the flow of the material being extruded is
indicated by the arrow A.
[0108] FIG. 3 is an image of a series of extruded agglomerates,
showing different cross-sectional geometries including inner
channels. Some of these extruded agglomerates have been made using
the nozzle designs of FIGS. 2a, 2b and 2c.
[0109] Tobacco constituent releasing components formed from such
shaped extruded agglomerate sections have an inner channel
structure which has advantageous adjustable strand ventilation
properties and a significantly enlarged inner surface leading to
improved heat and mass transfer. As a result, such components
exhibit better, more uniform release of flavor by evaporation.
Furthermore, the structure with inner channels exhibits
significantly improved strength in both the radial and axial
directions, which is beneficial for the further processing of the
extruded agglomerate, for example when it is cut into segments.
[0110] In some embodiments, the diameter of the tobacco constituent
releasing component is from about 4 mm to about 10 mm, or the
diameter may be from about 5 mm to about 8 mm.
[0111] In some embodiments, the tobacco constituent releasing
component is a cylindrical tobacco segment. In some embodiments the
cylinder has a diameter of from about 5 mm to about 8 mm and a
length of from about 5 mm to about 80 mm, from about 15 mm to about
50 mm, or from about 20 mm to about 30 mm.
[0112] By means of various nozzle designs and/or different process
parameters within the extruder, including the temperature, pressure
and shear forces, extruded agglomerates with different physical
properties may be prepared, including different heat transfer
properties, draft resistance, and capable of producing different
aerosols and/or of modifying aerosols being drawn through the
extruded agglomerate.
[0113] The make up of the precursor composition can also play a
very significant role in determining the physical and mechanical
properties of the extruded material and, as a consequence, of the
tobacco constituent releasing components.
[0114] In some embodiments, the extruded agglomerate is shaped upon
discharge from the extruder. In some embodiments, the extruded
agglomerate is cut to an initial length, for example, 1 meter, and
allowed to cool before then being cut into sections of the desired
length to provide tobacco constituent releasing components of the
desired dimensions.
[0115] In some embodiments, the extruded agglomerate may be cooled
just before or just as it leaves the extruder. In some embodiments,
the cooling is intensive and involves exposing the extruded
agglomerate, which will be at an elevated temperature, for example
from about 30.degree. C. to about 100.degree. C., or from about
40.degree. C. to about 70.degree. C., to a cooling means that will
reduce the temperature to within a range of from about 0.degree. C.
to about 25.degree. C., or from 5.degree. C. to about 15.degree. C.
This rapid cooling of the extruded agglomerate may enhance the
internal and external stability of the extruded agglomerate. In
some embodiments, it is the die that is cooled to achieve this
effect.
[0116] In some embodiments, it may be desirable to control the
temperature of the precursor composition during extrusion,
including before feeding the composition through the die. This is
especially the case where the precursor composition includes
temperature sensitive components, such as aerosol forming agents
such as glycerol. Thus, in some embodiments, extrusion of the
precursor composition includes reducing the temperature of the
precursor composition before it reaches the die. Such cooling of
the precursor composition may result in the formation of an
extruded agglomerate with beneficial properties, or may improve the
strand-shaping process, for example where channels are to be formed
within the extruded agglomerate strand.
[0117] In some embodiments, the precursor composition may be
granulated prior to extrusion. Where the precursor composition
includes multiple different types of particles, this granulation
step can enhance homogenization within the extruded agglomerate.
The granulated precursor composition may be fed into an extruder to
form the tobacco constituent releasing components.
[0118] Granulation of the precursor composition involves the
binding or fusing together of the particles of the precursor
composition to form larger, multi-particle entities which are
agglomerated structures. The multi-particle entities formed by
granulation are called granules and they may have various geometric
shapes, including, for example, the general form of spheres,
cylinders, and the like.
[0119] In one embodiment, the granulation step used is wet
granulation. In wet granulation, granules are formed by the
addition of a granulation liquid onto a powder bed. Agitation in
the system, along with the wetting of the components within the
precursor composition, results in the aggregation of the particles
to produce wet granules. The granulation liquid may be at least
partially removed by drying to provide dry granules. The
granulation liquid may be water-based or solvent-based. Suitable
granulation liquids include, for example, water, ethanol and
isopropanol, either alone or in combination. In some embodiments,
the granulation liquid comprises an aerosol forming agent, such as
glycerol.
[0120] In another embodiment, the granulation step used is dry
granulation. In dry granulation, granules are formed without using
a granulation liquid. This type of process has the advantage that
it does not expose the precursor composition to moisture and so
there is no requirement to expose the granules to heat in order to
dry them. Forming granules by dry granulation involves compacting
and densifying the precursor composition, usually under high
pressure.
[0121] In some embodiments, spheronisation is used to further
process extruded segments. These segments are typically
cylindrically-shaped and are cut or broken into uniform lengths
following extrusion. They are then gradually transformed into
spherical shapes by spheronisation. This shaping occurs as a result
of plastic deformation and spheronisation can lead to spherical
agglomerated structures, often with a nearly uniform diameter.
Incorporation into a Product
[0122] A tobacco industry product refers to any item made in, or
sold by the tobacco industry, typically including a) cigarettes,
cigarillos, cigars, tobacco for pipes or for roll-your-own
cigarettes, (whether based on tobacco, tobacco derivatives,
expanded tobacco, reconstituted tobacco or tobacco substitutes); b)
non-smoking products incorporating tobacco, tobacco derivatives,
expanded tobacco, reconstituted tobacco or tobacco substitutes such
as snuff, snus, hard tobacco, and heat-not-burn (HnB) products; and
c) other nicotine-delivery systems such as inhalers, aerosol
generation devices including e-cigarettes, lozenges and gum. This
list is not intended to be exclusive, but merely illustrates a
range of products which are made and sold in the tobacco
industry.
[0123] One or more of the tobacco constituent releasing components
disclosed herein may be incorporated into an aerosol provision
device. As used herein, an aerosol provision device includes vapor
devices such as e-cigarettes, devices for heating smokeable
material such as tobacco heating devices and Hybrid devices.
[0124] As used herein, the apparatus for heating smokeable material
to volatilize at least one component of the smokeable material
includes so-called "heat not burn" products or tobacco heating
devices or products, which release compounds by heating, but not
burning, smokeable material.
[0125] Hybrid devices are devices in which a liquid, such as a
nicotine-containing liquid or a nicotine-free liquid, is heated to
form an aerosol and this aerosol is then drawn through a smokeable
material, such as a tobacco segment, picking up tobacco flavors or
wherein a separate aerosol is formed by heating a smokeable
material. In some embodiments, the device includes a means for
heating the smokeable material directly, in addition to, or as an
alternative to, the heating of the smokeable material by the
aerosol formed by heating the liquid to form an aerosol.
[0126] The tobacco constituent releasing component may be
positioned within an apparatus or device so that the tobacco
constituents that are released become entrained in an aerosol
generated by the apparatus or device upon use, modifying the
properties of the aerosol, for example by imparting tobacco
constituents, including tobacco flavor, to that aerosol.
Additionally or alternatively, the tobacco constituent releasing
component may itself generate an aerosol during use, said aerosol
including the released tobacco constituents.
[0127] In some embodiments, an apparatus or device may be provided
with a filter having tobacco constituent releasing component
located within said filter. This may be in addition to or instead
of the apparatus or device including other tobacco constituent
releasing components.
[0128] In some embodiments the filter or filter element may
comprise a filter material which has a filtering effect. Suitable
filter material may include, for example, tow comprising or
consisting of cellulose acetate, polylactic acid, and/or other
suitable polymers, or the filter or filter element may comprise a
hard material such as plastic with holes.
[0129] In some embodiments where multiple tobacco constituent
releasing components are incorporated into a filter, this may be in
a "Dalmatian" style filter section, where the tobacco constituent
releasing components are dispersed throughout a fibrous filter plug
material. Alternatively, the tobacco constituent releasing
components may be located in a cavity within the filter. The cavity
may, for example, be a cavity section positioned between two (or
more) adjacent filter plugs or the cavity may be a pocket defined
within a filter plug. In such embodiments, the tobacco constituent
releasing components may be small in size, for example in the form
of granules.
[0130] In other embodiments, a larger, single tobacco constituent
releasing component is incorporated into a filter. For example, a
single tobacco constituent releasing component may be embedded in a
fibrous filter plug material.
[0131] Alternatively, the tobacco constituent releasing component
may be incorporated into a multi-segment filter, the tobacco
constituent releasing component itself making up one of the filter
segments. In such embodiments, the tobacco constituent releasing
component may have any shape or size, but it may be advantageous
for the component to a have a cylindrical shape and the dimensions
similar to or compatible with those of the filter segments. In some
embodiments, the tobacco constituent releasing component may be
surrounded by filter material such as a layer of fibrous filter
tow, to form a filter segment. In other embodiments, the tobacco
constituent releasing component may have the dimensions of a filter
plug and it may be incorporated into a filter with one or more
adjacent filter plugs. Alternatively, a tobacco constituent
releasing component may be included in a cavity section positioned
between two (or more) adjacent filter plugs.
[0132] In some embodiments the tobacco constituent releasing
component itself may be the filter element in the aerosol provision
device, it being capable of filtering condensates and other
particulate matter in the aerosol, before the aerosol is inhaled by
the user.
[0133] According to some embodiments, one or more tobacco
constituent releasing components are included in an aerosol
provision device or apparatus for heating smokeable material to
volatilize at least one component of the smokeable material in
which a tobacco segment is heated but not combusted (i.e., a
tobacco heating product or so-called Heat-not-Burn product). In
some of these products, the tobacco segment is heated to generate
an aerosol.
[0134] One option is to incorporate the one or more tobacco
constituent releasing components in the filter of such products. In
some embodiments, multiple tobacco constituent releasing components
are incorporated into the filter of a tobacco heating product. In
other embodiments, a single tobacco constituent releasing component
is incorporated into the filter of a tobacco heating product.
[0135] Another option is to incorporate one or more tobacco
constituent releasing components in the tobacco segment of such
products. In some embodiments, one or more tobacco constituent
releasing components may be incorporated into tobacco material to
form the tobacco segment. For example, the one or more tobacco
constituent releasing components may be dispersed within the
tobacco material, such as cut tobacco or reconstituted tobacco, to
contribute to the flavor imparted by the tobacco. In other
embodiments, the tobacco included in the tobacco segment of the
tobacco heating product consists or consists essentially of one or
more tobacco constituent releasing components. In one embodiment,
the tobacco segment heated by the tobacco heating product consists
of or consists essentially of one or more tobacco constituent
releasing component. The tobacco constituent releasing component
may be heated directly. Where the tobacco segment is multiple
tobacco constituent releasing components, these may be held in a
container or cartridge. At least portions of the container or
cartridge may be permeable to air, to allow air to flow over or
through the tobacco constituent releasing components.
[0136] FIG. 6 shows a cross-sectional view of an example of a
tobacco heating product for heating a smokeable material. The
apparatus 11 has a heating chamber 14 which in use contains the
smokeable material to be heated and volatilize d. In this
embodiment, the smokeable material is in the form of a monolithic
tobacco constituent releasing component 13. The smokeable material
could however be multiple tobacco constituent releasing components
held in the heating chamber or provided in a cartridge like the one
illustrated in FIG. 8.
[0137] The apparatus 11 of FIG. 6 further has an electronics/power
chamber 16 which may, for example, contain electrical control
circuitry and/or a power source (not shown). The electrical control
circuitry may include a controller, such as a microprocessor
arrangement, configured and arranged to control the heating of the
smokeable material via a heating element (not shown). The
electrical control circuitry may in use receive a signal from for
example a puff-actuated sensor which is sensitive to for example
changes in pressure or changes in rate of air flow that occur upon
initiation of a draw on the apparatus 11 by a user. The electrical
control circuitry can then operate so as to cause heating of the
smokeable material "on demand". Various arrangements for a
puff-actuated sensor are available, including for example a
thermistor, an electro-mechanical device, a mechanical device, an
optical device, an opto-mechanical device and a micro electro
mechanical systems (MEMS) based sensor. As an alternative, the
apparatus may have a manually operable switch for a user to
initiate a puff.
[0138] The heating chamber 14 is contained within the housing 12.
There may be a support and/or insulating means (not shown)
positioned between the heating chamber 14 and the housing 12, for
example to assist in heat-insulating the housing 12 from the
heating chamber 14, so that the housing 12 does not become hot or
at least too hot to touch during use.
[0139] The housing 12 includes an inlet 15 through which air is
drawn into the apparatus. The housing 12 also includes an outlet 17
at a mouthpiece 18 of the apparatus 11. Air is drawn into the
apparatus 11 through the inlet 15, travels through the apparatus
picking up tobacco constituents released by the tobacco constituent
releasing component 13, and the resulting aerosol generated by the
apparatus 11 leaves the apparatus 11 through the outlet 19 and is
inhaled by the user.
[0140] According to some embodiments, one or more tobacco
constituent releasing components are included in a so-called Hybrid
product for heating smokeable material to volatilize at least one
component of a smokeable material. In some of these products, the
tobacco segment is heated to generate an aerosol, in addition to
the heating of a liquid, such as a nicotine-containing liquid or a
nicotine-free liquid, which is heated by a heat source to form an
aerosol or vapor. In some Hybrid products, the aerosol or vapor
formed from the liquid is drawn over or through the tobacco
segment, picking up tobacco flavors. In other embodiments, the
aerosol or vapor formed from the liquid is not drawn over or
through the tobacco segment.
[0141] In Hybrid products that include a filter, one option is to
incorporate the tobacco constituent releasing components in the
filter of such products, in a similar manner to that described for
tobacco heating products. In some embodiments, multiple tobacco
constituent releasing components are incorporated into the filter
of a Hybrid product. In other embodiments, a single tobacco
constituent releasing component is incorporated into the filter of
a Hybrid product.
[0142] Where the smoking article is a so-called Hybrid product
another option is to incorporate the tobacco constituent releasing
components in the tobacco segment of such products. In some
embodiments, one or more tobacco constituent releasing components
may be incorporated into tobacco material to form the tobacco
segment. For example, the one or more tobacco constituent releasing
components may be dispersed within the tobacco material, such as
cut tobacco or reconstituted tobacco, to contribute to the flavor
imparted by the tobacco. In other embodiments, the tobacco included
in the tobacco segment of the Hybrid product consists of one or
more tobacco constituent releasing components. In one embodiment,
the tobacco segment in the Hybrid product consists of or consists
essentially of one or more tobacco constituent releasing
components.
[0143] FIG. 7 shows a cross-sectional view of an example of a
Hybrid product for heating a smokeable material and a liquid. The
apparatus 21 has a housing 22 containing a chamber 24 which in use
contains the smokeable material to be heated and volatilize d. In
this embodiment, the smokeable material is in the form of a
monolithic tobacco constituent releasing component 23. The
smokeable material could however be multiple tobacco constituent
releasing components held in the chamber or provided in a cartridge
like the one illustrated in FIG. 8. The housing 22 also contains a
liquid reservoir 25 containing a liquid 26 to be heated to form a
vapor.
[0144] The apparatus 21 further has an electronics/power chamber 27
which may, for example, contain electrical control circuitry and/or
a power source (not shown). The electrical control circuitry may
include a controller, such as a microprocessor arrangement,
configured and arranged to control the heating of the smokeable
material and of the liquid 26 via one or more heating elements (not
shown). The electrical control circuitry may allow the apparatus 21
to be puff-actuated, so as to cause heating of the smokeable
material "on demand". As an alternative, the apparatus 22 may have
a manually operable switch for a user to initiate a puff
[0145] The housing 22 also includes an inlet 28 through which air
is drawn into the apparatus. The housing 22 also includes an outlet
29 at a mouthpiece 30 of the apparatus 21. Air is drawn into the
apparatus 21 through the inlet 28, travels through the apparatus
picking up the vapor created by heating the liquid 26 in the liquid
reservoir 25, and tobacco constituents released by the tobacco
constituent releasing component 23, and the resulting aerosol
generated by the apparatus 21 leaves the apparatus 21 through the
outlet 29 and is inhaled by the user.
[0146] The Hybrid device 21 shown schematically in FIG. 7
represents just one possible configuration of such an apparatus.
The relative positions of the liquid reservoir 25 and the smokeable
material chamber 24 can be changed, as can the path of the air
flowing through the apparatus.
[0147] In one embodiment, the liquid reservoir is positioned
upstream of the smokeable material to be volatilize d.
Alternatively, the liquid reservoir may be positioned downstream of
the smokeable material to be volatilize d. In a yet further
arrangement, the two sources of aerosol in the apparatus may be
arranged side-by-side, etc.
[0148] In some embodiments, the vapor produced by heating the
liquid in the liquid reservoir flows over or through the smokeable
material comprising or consisting of one or more tobacco
constituent releasing components. In some embodiments, the elevated
temperature of the vapor causes the tobacco constituents to be
released. Alternatively or in addition, the smokeable material may
be separately heated by a heating means.
[0149] In some embodiments, a Hybrid device is provided in which
the vapor created by heating a liquid heats the smokeable material
in order to volatilize at least one component of the smokeable
material. In some embodiments, the liquid is a nicotine-free
liquid. In other embodiments, the liquid contains nicotine. Where
the smokeable material is heated by the vapor to volatilize at
least one component of the smokeable material, in certain
embodiments the device does not include a separate means for
heating the smokeable material. The smokeable material may comprise
or consist of at least one tobacco constituent releasing
component.
[0150] In other embodiments, the vapor produced by heating the
liquid in the liquid reservoir does not flows over or through the
smokeable material comprising or consisting of one or more tobacco
constituent releasing components. Rather, this vapor and the
aerosol generated by heating the smokeable material only mix after
they are both formed.
[0151] The tobacco heating products and Hybrid products described
herein may, in some embodiments, include tobacco segments in the
form of containers or cartridges containing one or more tobacco
constituent releasing components. These containers or cartridges
may be removable. They may replace both the chamber holding the
smokeable material and the smokeable material in the apparatus
described above with reference to FIGS. 6 and 7, and in the
alternative embodiments discussed.
[0152] Referring to FIG. 8, a tobacco segment cartridge 31 is
shown, comprising a housing 32 defining a cavity within which are
held one or more tobacco constituent releasing components according
to the disclosure (not shown). The housing 32 may, for example be
made from molded plastic or the like. In order to allow air drawn
through the device to pass into the cartridge 31 and over or
through the one or more tobacco constituent releasing components
and then out of the cartridge 31, ventilation holes 33 are provided
in the housing 32 of the cartridge 31. In some embodiments, the
cartridge 31 may further comprise heating means that is heatable by
a suitable means in order to heat the one or more tobacco
constituent releasing components held therein.
[0153] In some embodiments, one or more tobacco constituent
releasing components are incorporated into a filter or a filter
element for inclusion in a combustible smoking article.
[0154] As used herein, the term "combustible smoking article"
includes smokeable products such as cigarettes, cigars and
cigarillos whether based on tobacco, tobacco derivatives, expanded
tobacco, reconstituted tobacco or tobacco substitutes. The
combustible smoking articles include a rod of smokeable material
and a filter comprising at least one filter element.
[0155] As used herein, the term "combustible smoking article" does
not include Heat-not-Burn (HnB) products, or other nicotine
delivery products such as aerosol generation devices including
e-cigarettes or Hybrid products.
[0156] The tobacco constituent releasing component may be
positioned within the filter or within a filter element making up
the filter of the combustible smoking article, so that the released
tobacco constituents become entrained in an aerosol generated by
the smoking article upon use, modifying the properties of the
aerosol, for example by imparting tobacco constituents, including
tobacco flavor, to that aerosol.
[0157] Filters and filter elements for use in combustible smoking
articles include filter material to remove certain smoke
constituents from the mainstream smoke drawn through the smoking
article during use. The filter material is gathered together to
form a rod which is cut to form individual filter segments. The
filter for a smoking article may be made of one segment of filter
rod, or may be made from multiple filter elements, with or without
a cavity or spaces between them. A widely used filter material is a
continuous tow of filamentary cellulose acetate plasticized with
triacetin. Other filter materials can comprise at least one
material selected from polyvinyl alcohol (PVOH), polylactic acid
(PLA), poly(.epsilon.-caprolactone) (PCL), poly(1-4 butanediol
succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT),
starch based materials, paper, aliphatic polyester materials and
polysaccharide polymers in the form of sheets or fibers.
[0158] The filter can have a cylindrical shape and generally have a
length and an overall circumference to suit the type of combustible
smoking articles they are to be used in. Smoking articles such as
cigarettes and their formats are often named according to the
cigarette length: "regular" (typically in the range 68-75 mm, e.g.
from about 68 mm to about 72 mm), "short" or "mini" (68 mm or
less), "king-size" (typically in the range 75-91 mm, e.g. from
about 79 mm to about 88 mm), "long" or "super-king" (typically in
the range 91-105 mm, e.g. from about 94 mm to about 101 mm) and
"ultra-long" (typically in the range from about 110 mm to about 121
mm).
[0159] They are also named according to the cigarette
circumference: "regular" (about 23-25 mm), "wide" (greater than 25
mm), "slim" (about 22-23 mm), "demi-slim" (about 19-22 mm),
"super-slim" (about 16-19 mm), and "micro-slim" (less than about 16
mm). Accordingly, a cigarette in a king-size, super-slim format
will, for example, have a length of about 83 mm and a circumference
of about 17 mm. Cigarettes in the regular, king-size format have a
circumference of from 23 to 25 mm and an overall length of from 75
to 91 mm.
[0160] Each format may be produced with filters of different
lengths, smaller filters being generally used in formats of smaller
lengths and circumferences. Typically the filter length will be
from 15 mm, associated with short, regular formats, to 30 mm,
associated with ultra-long super-slim formats. The tipping paper
will have a greater length than the filter, for example from 3 to
10 mm longer.
[0161] Positioned within the filter of a combustible smoking
article, the tobacco constituent releasing components of this
disclosure are not exposed to significant temperature increases
during use of the smoking article. That said, the temperature
within the filter of a conventional cigarette does gradually
increase during use. In a conventional combustible smoking article,
such as a cigarette, and under normal smoking conditions, such as
the ISO smoking regime, the smoking may involve 8-9 puffs and the
first 5-6 puffs are accompanied by only slight increases in
temperature during the puffs. For example, the first puffs may be
accompanied by a temporary increase in temperature of in the region
of 1-5.degree. C., with the temperature remaining between 20 and
30.degree. C., and in some cases, between 23 and 26.degree. C.
During the final few puffs of a conventional combustible smoking
article, such as a cigarette, the temperature starts to increase
more during the puffs, with peaks starting to exceed 30.degree. C.,
and exceeding 60.degree. C. for the penultimate and last puffs.
[0162] This temperature change may be used to trigger or assist the
release of materials from the tobacco constituent releasing
component during use of the smoking article. For example, the rise
in temperature may help to volatilize remaining components which
have not been released during the first few puffs. Alternatively or
in addition, materials may be included in the tobacco constituent
releasing component specifically to be released or to enhance
release of tobacco constituents at these elevated temperatures.
[0163] According to some embodiments, multiple tobacco constituent
releasing components are incorporated into the filter element for a
combustible smoking article. In other embodiments, a single tobacco
constituent releasing component is incorporated into the filter
element.
[0164] Where multiple tobacco constituent releasing components are
incorporated into a filter, this may be in a "Dalmatian" style
filter section, where the tobacco constituent releasing components
are dispersed throughout a fibrous filter plug material.
[0165] Such an arrangement is shown in FIG. 9. Referring to FIG. 9,
a smoking article 21 comprises a filter 22 and a cylindrical rod of
smokeable material 23, such as tobacco, aligned with the filter 22
such that one end of the smokeable material rod 23 abuts the end of
the filter 22. The filter 22 is wrapped in a plug wrap (not shown)
and the smokeable material rod 23 is joined to the filter 22 by
tipping paper in a conventional manner. The filter 22 is
substantially cylindrical and comprises filter material 24
throughout which are dispersed tobacco constituent releasing
components 25.
[0166] Alternatively, the tobacco constituent releasing components
may be located in a cavity within the filter. The cavity may, for
example, be a cavity section positioned between two (or more)
adjacent filter plugs or the cavity may be a pocket defined within
a filter plug. In such embodiments, the tobacco constituent
releasing components may be small in size, for example in the form
of granules.
[0167] In other embodiments, larger, monolithic tobacco constituent
releasing components are incorporated into a filter. For example, a
single tobacco constituent releasing component may be embedded in a
fibrous filter plug material.
[0168] Such an arrangement is shown in FIG. 10, which shows a
smoking article 21 comprising a filter 22 and a cylindrical rod of
smokeable material 23, wherein the filter 22 comprises a tobacco
constituent releasing component 26 which is surrounded by filter
material 24.
[0169] Alternatively, the tobacco constituent releasing component
may be incorporated into a multi-segment filter, the tobacco
constituent releasing component itself making up one of the filter
segments. In such embodiments, the tobacco constituent releasing
component may have any shape or size, but it may be advantageous
for the component to a have a cylindrical shape and the dimensions
similar to or compatible with those of the filter segments. In some
embodiments, the tobacco constituent releasing component may be
surrounded by filter material such as a layer of fibrous filter
tow, to form a filter segment. In other embodiments, the tobacco
constituent releasing component may have the dimensions of a filter
plug and it may be incorporated into a filter with one or more
adjacent filter plugs. Alternatively, a tobacco constituent
releasing component may be included in a cavity section positioned
between two (or more) adjacent filter plugs.
[0170] Referring to FIG. 11, a smoking article 21 comprises a
filter 22 and a cylindrical rod of smokeable material 23, wherein
the filter 22 is made up of multiple filter segments. There is a
filter segment 27 positioned at the mouth end of the filter and a
filter segment 28 positioned at the tobacco rod end of the filter.
Positioned between these filter segments, which comprise filter
material 24, is a tobacco constituent releasing component 26.
[0171] The filters and filter elements of the present disclosure
may, in some embodiments, further comprise additives. For example,
the additive may be particles of adsorbent material, including, for
example, activated carbon, an ion exchange resin, such as CR20,
zeolite, silica gel, meerschaum, aluminum oxide (activated or not),
carbonaceous resin, magnesium silicate, including Sepiolite
(Mg.sub.4Si.sub.6O.sub.15(OH).sub.2.6H.sub.2O) and combinations
thereof.
[0172] Where the smoking article filter comprises an adsorbent, in
some embodiments the tobacco constituent releasing component is
positioned downstream of the adsorbent.
[0173] In order to address various issues and advance the art, the
entirety of this disclosure shows by way of illustration various
embodiments in which the claimed invention(s) may be practiced and
provide for superior tobacco constituent releasing components and
tobacco industry products including the same. The advantages and
features of the disclosure are of a representative sample of
embodiments only, and are not exhaustive and/or exclusive. They are
presented only to assist in understanding and teach the claimed
features. It is to be understood that advantages, embodiments,
examples, functions, features, structures, and/or other aspects of
the disclosure are not to be considered limitations on the
disclosure as defined by the claims or limitations on equivalents
to the claims, and that other embodiments may be utilized and
modifications may be made without departing from the scope and/or
spirit of the disclosure. Various embodiments may suitably
comprise, consist of, or consist essentially of, various
combinations of the disclosed elements, components, features,
parts, steps, means, etc. In addition, the disclosure includes
other inventions not presently claimed, but which may be claimed in
future.
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