U.S. patent application number 17/629921 was filed with the patent office on 2022-08-11 for aerosol generation.
The applicant listed for this patent is Nicoventures Trading Limited. Invention is credited to Ludwig Friedrich.
Application Number | 20220248743 17/629921 |
Document ID | / |
Family ID | 1000006358061 |
Filed Date | 2022-08-11 |
United States Patent
Application |
20220248743 |
Kind Code |
A1 |
Friedrich; Ludwig |
August 11, 2022 |
AEROSOL GENERATION
Abstract
An aerosol generating article for use in an aerosol generating
assembly, the aerosol generating article including an aerosol
generating substrate having an aerosol generating material, wherein
the aerosol generating material is solid and includes a starch and
a plasticizer, wherein the amount of plasticizer is from about 5%
to 70% by weight of the starch.
Inventors: |
Friedrich; Ludwig; (London,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nicoventures Trading Limited |
London |
|
GB |
|
|
Family ID: |
1000006358061 |
Appl. No.: |
17/629921 |
Filed: |
July 31, 2020 |
PCT Filed: |
July 31, 2020 |
PCT NO: |
PCT/EP2020/071647 |
371 Date: |
January 25, 2022 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24B 15/285 20130101;
A24B 15/14 20130101; A24B 15/186 20130101; A24B 3/14 20130101; A24B
15/167 20161101; A24B 15/302 20130101 |
International
Class: |
A24B 15/14 20060101
A24B015/14; A24B 15/30 20060101 A24B015/30; A24B 15/167 20060101
A24B015/167; A24B 15/28 20060101 A24B015/28; A24B 15/18 20060101
A24B015/18; A24B 3/14 20060101 A24B003/14 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 31, 2019 |
GB |
1910952.9 |
Claims
1. An aerosol generating article for use in an aerosol generating
assembly, the article comprising an aerosol generating substrate
comprising an aerosol generating material, wherein the aerosol
generating material is solid and comprises a starch and a
plasticizer, wherein the amount of plasticizer is from about 5% to
70% by weight of the starch.
2. The aerosol generating article according to claim 1, wherein the
amount of plasticizer is from about 20% to 50% by weight of the
starch.
3. The aerosol generating article according to claim 1, wherein the
aerosol generating material further comprises a tobacco
material.
4. The aerosol generating article according to claim 3, wherein the
tobacco material comprises a powdered tobacco material having a
particle size of less than about 250 .mu.m.
5. The aerosol generating article according to claim 3, wherein the
tobacco material comprises a tobacco extract.
6. The aerosol generating article according to claim 1, wherein the
plasticizer is selected from erythritol, sorbitol, glycerol,
glycols such as propylene glycol, monohydric alcohols, high boiling
point hydrocarbons, lactic acid, diacetin, triacetin, triethylene
glycol diacetate, triethyl citrate, ethyl myristate, isopropyl
myristate, methyl stearate, dimethyl dodecanedioate and dimethyl
tetradecanedioate.
7. The aerosol generating article according to claim 1, wherein the
starch comprises potato starch.
8. The aerosol generating article according to claim 1, wherein the
solid aerosol generating material is formed as a sheet.
9. The aerosol generating article according to claim 1, wherein the
aerosol generating material has a mass per unit area of 80-120
g/m.sup.2.
10. The aerosol generating article according to claim 1, wherein
the aerosol generating substrate comprises a carrier on which the
aerosol generating material is provided.
11. An aerosol generating assembly comprising the aerosol
generating article according claim 1 and a heater configured to
heat the aerosol generating material without burning the aerosol
generating material.
12. A starch matrix material comprising; a plasticizer wherein the
amount of plasticizer is from about 5% to 70% by weight of the
starch; and a plant-derived flavor or aroma component.
13. A kit comprising the aerosol generating article according to
claim 1 and a device which is configured to receive the article in
use, the device comprising a heater which is configured to heat the
aerosol generating material without burning the aerosol generating
material during use.
14. A method of making the aerosol generating article of claim 1,
the method comprising; (i) mixing the constituent parts of the
aerosol generating material in a slurry, heating and stirring the
slurry to effect gelation, casting the gel and drying by heating to
form the aerosol generating material; and (ii) incorporating the
aerosol generating material in the aerosol generating article.
15. A slurry comprising: a starch; a plasticizer wherein the amount
of plasticizer is from about 5% to 70% by weight of the starch; and
a plant-derived flavor or aroma component; and water, wherein a
weight ratio of water to a total weight of other ingredients is
between about 10:1 and 20:1.
16. A slurry comprising: a starch; a plasticizer, wherein the
amount of plasticizer is from about 5% to 70% by weight of the
starch; a powdered tobacco material having a mean particle diameter
of less than about 250 .mu.m, wherein an amount of powdered tobacco
material is from about 40% to 300% by weight of the starch; and
water, wherein a weight ratio of water to a total weight of other
ingredients is between about 10:1 and 20:1.
17. A slurry comprising: a starch; a plasticizer, wherein an amount
of plasticizer is from about 5% to 70% by weight of the starch; and
an aqueous tobacco extract, wherein a weight ratio of the aqueous
tobacco extract to a total weight of other ingredients is between
about 10:1 and 20:1.
18. A smoking article comprising a wrapper, wherein the wrapper
comprises a starch matrix and a plasticizer, wherein the amount of
plasticizer is from about 5% to 30% by weight of the starch and
wherein the smoking article is a combustible or a non-combustible
smoking article.
19. A filter for a smoking article, the filter comprising a starch
matrix and a plasticizer, wherein the amount of plasticizer is from
about 5% to 15% by weight of the starch and the smoking article is
a combustible or non-combustible smoking article.
20. A smoking article or aerosol generating article comprising the
filter according to claim 19.
Description
PRIORITY CLAIM
[0001] The present application is a National Phase entry of PCT
Application No. PCT/EP2020/071647, filed Jul. 31, 2020, which
claims priority from Great Britain Application No. 1910952.9, filed
Jul. 31, 2019, each of which is hereby fully incorporated herein by
reference.
TECHNICAL FIELD
[0002] The present invention relates to aerosol generation.
BACKGROUND
[0003] Smoking articles such as cigarettes, cigars and the like
burn tobacco during use to create tobacco smoke. Alternatives to
these types of articles release an inhalable aerosol or vapor by
releasing compounds from a substrate material by heating without
burning. These may be referred to as non-combustible smoking
articles or aerosol generating assemblies.
[0004] One example of such a product is a heating device which
release compounds by heating, but not burning, a solid
aerosolizable material. This solid aerosolizable material may, in
some cases, contain a tobacco material. The heating volatilizes at
least one component of the material, typically forming an inhalable
aerosol. These products may be referred to as heat-not-burn
devices, tobacco heating devices or tobacco heating products.
Various different arrangements for volatilizing at least one
component of the solid aerosolizable material are known.
[0005] Another known type of aerosol generating assembly is an
electronic cigarette or e-cigarette. In these devices, a liquid or
gel aerosol generating material is heated without burning. This
vaporizes one component of the material to form an inhalable vapor
or aerosol. The liquid or gel material may comprise nicotine.
[0006] As another example, there are e-cigarette/tobacco heating
product hybrid devices, also known as electronic tobacco hybrid
devices. These hybrid devices contain a liquid source (which may or
may not contain nicotine) which is vaporized by heating to produce
an inhalable vapor or aerosol. The device additionally contains a
solid aerosolizable material (which may or may not contain a
tobacco material) and components of this material are entrained in
the inhalable vapor or aerosol to produce the inhaled medium.
SUMMARY
[0007] A first aspect of the invention provides an aerosol
generating article for use in an aerosol generating assembly, the
article comprising an aerosol generating substrate comprising an
aerosol generating material, wherein the aerosol generating
material is solid and comprises a starch and a plasticizer, wherein
the amount of plasticizer is from about 5% to 70% by weight of the
starch.
[0008] A second aspect of the invention provides an aerosol
generating assembly comprising an aerosol generating article
according to the first aspect and a heater which is configured to
heat but not burn the aerosol generating material.
[0009] A third aspect of the invention provides starch matrix
material comprising; [0010] a plasticizer wherein the amount of
plasticizer is from about 5% to 70% by weight of the starch; and
[0011] a plant-derived flavor or aroma component.
[0012] A fourth aspect of the invention a kit comprising an aerosol
generating article according to the first aspect and a device which
is configured to receive the article in use, the device comprising
a heater which is configured to heat but not burn the aerosol
generating material in use.
[0013] A fifth aspect of the invention provides a method of making
an aerosol generating article according to the first aspect, the
method comprising;
[0014] (i) mixing the constituent parts of the aerosol generating
material in a slurry, heating and stirring the slurry to effect
gelation, casting the gel and drying by heating to form the aerosol
generating material; and
[0015] (ii) incorporating the aerosol generating material in an
aerosol generating article.
[0016] The invention also provides a slurry comprising: [0017] a
starch; [0018] a plasticizer wherein the amount of plasticizer is
from about 5% to 70% by weight of the starch; and [0019] a
plant-derived flavor or aroma component; and [0020] water.
[0021] Suitably, the weight ratio of water to the total weight of
the other ingredients is between about 10:1 and 20:1.
[0022] The invention also provides a slurry comprising: [0023] a
starch; [0024] a plasticizer, wherein the amount of plasticizer is
from about 5% to 70% by weight of the starch; [0025] a powdered
tobacco material having a mean particle diameter of less than about
250 .mu.m, wherein the amount of powdered tobacco material is from
about 40% to 300% by weight of the starch; [0026] water, wherein
the weight ratio of water to the total weight of the other
ingredients is between about 10:1 and 20:1.
[0027] The invention also provides a slurry comprising [0028] a
starch; [0029] a plasticizer, wherein the amount of plasticizer is
from about 5% to 70% by weight of the starch; [0030] an aqueous
tobacco extract, wherein the weight ratio of the aqueous tobacco
extract to the total weight of the other ingredients is between
about 10:1 and 20:1.
[0031] Further aspects of the invention include; [0032] (i) a
wrapper for a smoking article or aerosol generating article,
wherein the wrapper comprises a starch matrix and a plasticizer,
wherein the amount of plasticizer is from about 5% to 30% by weight
of the starch; and [0033] (ii) a filter for a smoking article or
aerosol generating article, the filter comprising a starch matrix
and a plasticizer, wherein the amount of plasticizer is from about
5% to 15% by weight of the starch.
[0034] The invention also provides articles including the above
wrapper and/or filter.
[0035] Further aspects, features and advantages of the invention
will become apparent from the following description, given by way
of example only, and with reference to the accompanying figures.
Features described herein in relation to one aspect are explicitly
disclosed in combination with other aspects of the invention, to
the extent that they are compatible.
BRIEF DESCRIPTION OF THE FIGURES
[0036] FIG. 1 shows a section view of an example of an aerosol
generating article.
[0037] FIG. 2 shows a perspective view of the article of FIG.
1.
[0038] FIG. 3 shows a sectional elevation of an example of an
aerosol generating article.
[0039] FIG. 4 shows a perspective view of the article of FIG.
3.
[0040] FIG. 5 shows a perspective view of an example of an aerosol
generating assembly.
[0041] FIG. 6 shows a section view of an example of an aerosol
generating assembly.
[0042] FIG. 7 shows a perspective view of an example of an aerosol
generating assembly.
DETAILED DESCRIPTION
[0043] The aerosol generating material described herein is "solid".
However, it may be a solid that retains within it some fluid such
as liquid. The solid may be a gel. It may be referred to as a
"dried gel". It may also be referred to as a "starch matrix".
[0044] As described above, the invention provides an aerosol
generating article for use in an aerosol generating assembly, the
article comprising an aerosol generating substrate comprising an
aerosol generating material, wherein the aerosol generating
material is solid and comprises a starch and a plasticizer, wherein
the amount of plasticizer is from about 5% to 70% by weight of the
starch.
[0045] The inventors have found that materials having this
composition can be efficiently heated to generate an inhalable
aerosol.
[0046] Starch forms a helical structure and small molecules such as
flavors and aromas are able to bind within this helix. However,
release of these molecules requires the helix to be heated so that
it unwinds. The aerosol generating material described herein is
formed by heating and dissolving starch and mixing with a
plasticizer. This plasticizer embeds within the starch. As the
starch then cools, retrogradation (realignment into the crystalline
helical form) is inhibited by the glycerol, resulting in an
irregular starch matrix which the small molecules can bind to. The
release temperatures for these small molecules is lower than for
the regular crystalline structure.
[0047] The inventors have established that such starch matrix
materials (comprising plasticizer in the claimed range) are
suitable for use as aerosol generating materials in non-combustible
smoking articles.
[0048] Any starch may be used in the invention. Suitably, the
starch may be a soluble starch, suitably a non-modified soluble
starch. Suitably the starch may be a derived from a gluten-free
product. The starch may comprise potato starch. This material is
readily available. The inventors have established that the use of
starch as a matrix material is preferable as compared to other
materials such as alginates and pectins, since these other
components require the addition of a setting agent (e.g. a calcium
source) to form the matrix; starch requires no such additional
agent. Alginates and pectins also contribute off-notes to the
flavor/aroma of the generated aerosol, and the use of starch as the
matrix material has been found to reduce this effect. Starch also
has a higher loading capacity. Starch materials are also typically
less tacky than comparable alginate or pectin materials, easing
manufacture and handling.
[0049] The amount of plasticizer is from about 5% to 70% by weight
of the starch. Suitably, the amount of plasticizer may be from
about 5%, 10%, 15% or 20% to about 70%, 60% or 50% by weight of the
starch. If the plasticizer content is too low, the resulting matrix
may be brittle, and/or the starch helical structure may be
relatively ordered meaning that any small molecules bound in the
helix may be difficult to release in use. Conversely, if the
plasticizer content is too high, the resulting matrix may be tacky
and difficult to handle, and/or the matrix may be so disordered
that any bound small molecules are released too readily in use.
Further, if the content of the plasticizer is too high, the
material may absorb water (as the plasticizer is hygroscopic)
resulting in a material that does not create an appropriate
consumption experience in use.
[0050] Further, the plasticizer content specified herein provides
an aerosol generating material with a flexibility that allows a
sheet of the material to be wound onto a bobbin, which is useful in
manufacture of aerosol generating articles.
[0051] In some cases, the plasticizer may be an aerosol generating
agent. Suitably, the plasticizer comprises one or more compound
selected from erythritol, sorbitol, glycerol, glycols such as
propylene glycol, monohydric alcohols, high boiling point
hydrocarbons, lactic acid, diacetin, triacetin, triethylene glycol
diacetate, triethyl citrate, ethyl myristate, isopropyl myristate,
methyl stearate, dimethyl dodecanedioate and dimethyl
tetradecanedioate. Suitably, the plasticizer may comprise one or
more of erythritol, propylene glycol, glycerol, triacetin, sorbitol
and xylitol. In some cases, the aerosol generating agent comprises,
consists essentially of or consists of glycerol.
[0052] The aerosol generating material may, in some cases, be a
hydrogel and comprises less than about 20 wt %, 15 wt %, 12 wt % or
10 wt % of water calculated on a wet weight basis (WWB). In some
cases, the material may comprise at least about 1 wt %, 2 wt % or 5
wt % of water (WWB). In some cases, the amorphous solid comprises
from about 1 wt % to about 15 wt % water, or from about 5 wt % to
about 15 wt % calculated on a wet weight basis. Suitably, the water
content of the amorphous solid may be from about 5 wt %, 7wt % or 9
wt % to about 15 wt %, 13 wt % or 11 wt % (WWB), most suitably
about 10 wt %. This water level ensures that the material is
relatively resistant to microbial degradation (such as mold
growth).
[0053] The aerosol generating material may further comprise a
plant-derived flavor or aroma component. In some cases, this may be
a powdered plant-derived component, and may have a particle size of
less than about 250 .mu.m, suitably less than about 200 .mu.m or
150 .mu.m (that is, the powder has been sieved and passes through a
sieve with that pore size). In some cases, the powder may have a
mean particle diameter of less than about 250 .mu.m, suitably less
than about 200 .mu.m or 150 .mu.m. The inventors have found that if
a powder is incorporated into the matrix structure, it is desirable
to have a particle size as specified --a larger particle size
disrupts the starch matrix and any bound small molecules are
released too readily in use.
[0054] The amount of the powder component may suitably be from
about 40% to about 300% by weight of the starch, more suitably from
about 50% to about 200% or 100% by weight of the starch.
[0055] In some cases, the amorphous solid comprises an active
substance. For example, in some cases, the amorphous solid
comprises a tobacco material and/or nicotine. For example, the
amorphous solid may additionally comprise powdered tobacco (having
a particle size (or mean diameter) as discussed above) and/or
nicotine and/or a tobacco extract. In such cases, nicotine and/or
tobacco aroma/flavor components of the extract may be bound to the
starch. In some cases, the amorphous solid may comprise from about
1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 80 wt
%, 70 wt %, 50 wt %, 45 wt % or 40 wt % (calculated on a dry weight
basis) of active substance. In some cases, the amorphous solid may
comprise from about 1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25
wt % to about 80 wt %, 70 wt %, 60 wt %, 50 wt %, 45 wt % or 40 wt
% (calculated on a dry weight basis) of a tobacco material and/or
nicotine.
[0056] In some cases, the amorphous solid comprises an active
substance such as tobacco extract. In some cases, the amorphous
solid may comprise 5-60 wt % (calculated on a dry weight basis) of
tobacco extract. In some cases, the amorphous solid may comprise
from about 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 55
wt %, 50 wt %, 45 wt % or 40 wt % (calculated on a dry weight
basis) tobacco extract. For example, the amorphous solid may
comprise 5-60 wt %, 10-55 wt % or 25-55 wt % of tobacco extract.
The tobacco extract may contain nicotine at a concentration such
that the amorphous solid comprises 1 wt % 1.5 wt %, 2 wt % or 2.5
wt % to about 6 wt %, 5 wt %, 4.5 wt % or 4 wt % (calculated on a
dry weight basis) of nicotine. In some cases, there may be no
nicotine in the amorphous solid other than that which results from
the tobacco extract.
[0057] In cases where the amorphous solid includes a tobacco
extract, it may be an aqueous extract, obtained by extraction with
water. In some cases, the tobacco extract may be within the
plasticizer as a solvent (i.e. obtained by extraction using the
plasticizer). The tobacco extract may be an extract from any
suitable tobacco, such as single grades or blends, cut rag or whole
leaf, including Virginia and/or Burley and/or Oriental. It may also
be an extract from tobacco particle `fines` or dust, expanded
tobacco, stems, expanded stems, and other processed stem materials,
such as cut rolled stems. The extract may be obtained from a ground
tobacco or a reconstituted tobacco material.
[0058] In some cases, the aerosol generating material may comprises
a flavorant. In some cases, the flavor (if present) comprises,
consists essentially of or consists of menthol. Suitably, the
amorphous solid may comprise up to about 60 wt %, 50 wt %, 40 wt %,
30 wt %, 20 wt %, 10 wt % or 5 wt % of a flavor. In some cases, the
amorphous solid may comprise at least about 0.5 wt %, 1 wt %, 2 wt
%, 5 wt % 10 wt %, 20 wt % or 30 wt % of a flavor (all calculated
on a dry weight basis). For example, the amorphous solid may
comprise 0.1-60 wt %, 1-60 wt %, 5-60 wt %, 10-60 wt %, 20-50 wt %
or 30-40 wt % of a flavor. In some cases, the flavor (if present)
comprises, consists essentially of or consists of menthol. In some
cases, the amorphous solid does not comprise a flavor.
[0059] In some embodiments, the amorphous solid comprises less than
60 wt % of a filler, such as from 1 wt % to 60 wt %, or 5 wt % to
50 wt %, or 5 wt % to 30 wt %, or 10 wt % to 20 wt %.
[0060] In other embodiments, the amorphous solid comprises less
than 20 wt %, suitably less than 10 wt % or less than 5 wt % of a
filler. In some cases, the amorphous solid comprises less than 1 wt
% of a filler, and in some cases, comprises no filler. In some
embodiments, the amorphous solid does not comprise tobacco fibers.
In particular embodiments, the amorphous solid does not comprise
fibrous material.
[0061] The filler, if present, may comprise one or more inorganic
filler materials, such as calcium carbonate, perlite, vermiculite,
diatomaceous earth, colloidal silica, magnesium oxide, magnesium
sulphate, magnesium carbonate, and suitable inorganic sorbents,
such as molecular sieves. The filler may comprise one or more
organic filler materials such as wood pulp, cellulose and cellulose
derivatives. In particular cases, the amorphous solid comprises no
calcium carbonate such as chalk.
[0062] In particular embodiments which include filler, the filler
is fibrous. For example, the filler may be a fibrous organic filler
material such as wood pulp, hemp fiber, cellulose or cellulose
derivatives. Without wishing to be bound by theory, it is believed
that including fibrous filler in an amorphous solid may increase
the tensile strength of the material. This may be particularly
advantageous in examples wherein the amorphous solid is provided as
a sheet, such as when an amorphous solid sheet circumscribes a rod
of aerosolizable material.
[0063] In some cases, the aerosol generating material may consist
essentially of, or consist of a starch, a plasticizer, water and
optionally a plant-derived flavor or aroma component, and
optionally a flavorant. In some cases, the aerosol generating
material may consist essentially of, or consist of potato starch,
glycerol, a tobacco material and water.
[0064] In some cases, the aerosol generating substrate may
additionally comprise a carrier on which the aerosol generating
material solid is provided. This carrier may ease manufacture
and/or handling through, for example, (a) providing a surface onto
which a slurry may be cast (and which the slurry does not need to
be separated from later), (b) providing a non-tacky surface for the
aerosol generating substrate easing handling, (c) providing some
rigidity to the substrate.
[0065] In some cases, the carrier may be formed from materials
selected from metal foil, paper, carbon paper, greaseproof paper,
ceramic, carbon allotropes such as graphite and graphene, plastic,
cardboard, wood or combinations thereof. In some cases, the carrier
may comprise or consist of a tobacco material, such as a sheet of
reconstituted tobacco. In some cases, the carrier may be formed
from materials selected from metal foil, paper, cardboard, wood or
combinations thereof. In some cases, the carrier itself be a
laminate structure comprising layers of materials selected from the
preceding lists. In some cases, the carrier may also function as a
flavor carrier. For example, the carrier may be impregnated with a
flavorant or with tobacco extract.
[0066] In some cases, the carrier may be substantially or wholly
impermeable to gas and/or aerosol. This prevents aerosol or gas
passage through the carrier in use, thereby controlling the flow
and ensuring it is delivered to the user. This can also be used to
prevent condensation or other deposition of the gas/aerosol in use
on, for example, the surface of a heater provided in an aerosol
generating assembly. Thus, consumption efficiency and hygiene can
be improved in some cases.
[0067] In some cases, the carrier in the aerosol generating article
may comprise or consist of a porous layer that abuts the starch
matrix. For example, the porous layer may be a paper layer. In some
particular cases, the starch layer is disposed in direct contact
with the porous layer; the porous layer abuts the starch and forms
a strong bond. The starch matrix is formed by drying a gel and,
without being limited by theory, it is thought that the slurry from
which the gel is formed partially impregnates the porous layer
(e.g. paper) so that when the gel sets and forms cross-links, the
porous layer is partially bound into the gel. This provides a
strong binding between the gel and the porous layer (and between
the dried gel and the porous layer).
[0068] Additionally, surface roughness may contribute to the
strength of bond between the aerosol generating material and the
carrier. The inventors have found that the paper roughness (for the
surface abutting the carrier) may suitably be in the range of
50-1000 Bekk seconds, suitably 50-150 Bekk seconds, suitably 100
Bekk seconds (measured over an air pressure interval of 50.66-48.00
kPa). (A Bekk smoothness tester is an instrument used to determine
the smoothness of a paper surface, in which air at a specified
pressure is leaked between a smooth glass surface and a paper
sample, and the time (in seconds) for a fixed volume of air to seep
between these surfaces is the "Bekk smoothness".)
[0069] Conversely, the surface of the carrier facing away from the
aerosol generating material may be arranged in contact with the
heater, and a smoother surface may provide more efficient heat
transfer. Thus, in some cases, the carrier is disposed so as to
have a rougher side abutting the aerosol generating material and a
smoother side facing away from the aerosol generating material.
[0070] In one particular case, the carrier may be a paper-backed
foil; the paper layer abuts the aerosol generating material and the
properties discussed in the previous paragraphs are afforded by
this abutment. The foil backing is substantially impermeable,
providing control of the aerosol flow path. A metal foil backing
may also serve to conduct heat to the aerosol generating
material.
[0071] In another case, the foil layer of the paper-backed foil
abuts the amorphous solid. The foil is substantially impermeable,
thereby preventing water provided in the amorphous solid to be
absorbed into the paper which could weaken its structural
integrity.
[0072] In some cases, the carrier is formed from or comprises metal
foil, such as aluminum foil. A metallic carrier may allow for
better conduction of thermal energy to the amorphous solid.
Additionally, or alternatively, a metal foil may function as a
susceptor in an induction heating system. In particular
embodiments, the carrier comprises a metal foil layer and a support
layer, such as cardboard. In these embodiments, the metal foil
layer may have a thickness of less than 20 .mu.m, such as from
about 1 .mu.m to about 10 .mu.m, suitably about 5 .mu.m.
[0073] In some cases, the carrier may be magnetic. This
functionality may be used to fasten the carrier to the assembly in
use. In some cases, the aerosol generating substrate may comprise
one or more magnets which can be used to fasten the substrate to an
induction heater in use.
[0074] In some cases, the aerosol generating substrate may comprise
heating means embedded in the aerosol generating material, such as
resistive or inductive heating elements.
[0075] In some cases, the amorphous solid may have a thickness of
about 0.015 mm to about 1.0 mm. Suitably, the thickness may be in
the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or
0.3 mm. The inventors have found that a material having a thickness
of 0.2 mm is particularly suitable. The inventors have established
that if the aerosol generating material is too thick, then heating
efficiency is compromised. This adversely affects the power
consumption in use. Conversely, if the material is too thin, it is
difficult to manufacture and handle; a very thin material is harder
to cast and may be fragile, compromising aerosol formation in use.
In some cases, the thickness stipulated herein is a mean thickness
for the material. In some cases, the layer thickness may vary by no
more than 25%, 20%, 15%, 10%, 5% or 1%.
[0076] The aerosol generating material may be formed as a sheet. It
may be incorporated into the article in sheet form. In some cases,
the aerosol generating material may be included as a planar sheet,
as a bunched or gathered sheet, as a crimped sheet, or as a rolled
sheet (i.e. in the form of a tube). In some cases, the sheet may be
used as a wrapping material, which at least partially circumscribes
other elements of the aerosol generating article, such as another
aerosolizable material (e.g. tobacco). In some other cases, the
aerosol generating material may be formed as a sheet and then
shredded and incorporated into the article. In some cases, the
shredded sheet may be mixed with cut rag tobacco and incorporated
into the article.
[0077] The aerosol generating material comprising the amorphous
solid may have any suitable area density, such as from 30 g/m.sup.2
to 120 g/m.sup.2. In some embodiments, aerosol generating material
may have an area density of from about 30 to 70 g/m.sup.2, or about
40 to 60 g/m.sup.2. In some embodiments, the amorphous solid may
have an area density of from about 80 to 120 g/m.sup.2, or from
about 70 to 110 g/m.sup.2, or particularly from about 90 to 110
g/m.sup.2. Such area densities may be particularly suitable where
the aerosol-generating material is included in an aerosol
generating article/assembly in sheet form, or as a shredded sheet
(described further herein below). For example, an aerosol
generating material having a mass per unit area of 80-120 g/m.sup.2
has a density comparable to cut rag tobacco, and so a mixture of
these components does not readily separate.
[0078] In some examples, the amorphous solid in sheet form may have
a tensile strength of from around 200 N/m to around 900 N/m. In
some examples, such as where the amorphous solid does not comprise
a filler, the amorphous solid may have a tensile strength of from
200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. Such
tensile strengths may be particularly suitable for embodiments
wherein the aerosol generating material is formed as a sheet and
then shredded and incorporated into an aerosol generating article.
In some examples, such as where the amorphous solid comprises a
filler, the amorphous solid may have a tensile strength of from 600
N/m to 900 N/m, or from 700 N/m to 900 N/m, or around 800 N/m. Such
tensile strengths may be particularly suitable for embodiments
wherein the aerosol generating material is included in an aerosol
generating article/assembly as a rolled sheet, suitably in the form
of a tube.
[0079] In some cases, the article may additionally comprise a
filter and/or cooling element. In some cases, the aerosol
generating article may be circumscribed by a wrapping material such
as paper.
[0080] A second aspect of the invention provides an aerosol
generating assembly comprising an aerosol generating article
according to the first aspect of the invention and a heater
configured to heat but not burn the aerosol generating
material.
[0081] The heater may be, in some cases, a thin film, electrically
resistive heater. In other cases, the heater may comprise an
induction heater or the like. The heater may be a combustible heat
source or a chemical heat source which undergoes an exothermic
reaction to product heat in use. The aerosol generating assembly
may comprise a plurality of heaters. The heater(s) may be powered
by a battery.
[0082] In some cases, the heater may heat, without burning, the
aerosolizable material to between 120.degree. C. and 350.degree. C.
in use. In some cases, the heater may heat, without burning, the
aerosolizable material to between 140.degree. C. and 250.degree. C.
in use. In some cases in use, substantially all of the amorphous
solid is less than about 4 mm, 3 mm, 2 mm or 1 mm from the heater.
In some cases, the solid is disposed between about 0.010 mm and 2.0
mm from the heater, suitably between about 0.02 mm and 1.0 mm,
suitably 0.1 mm to 0.5 mm. These minimum distances may, in some
cases, reflect the thickness of a carrier that supports the
amorphous solid. In some cases, a surface of the amorphous solid
may directly abut the heater.
[0083] In some cases, the heater may be embedded in the aerosol
generating substrate. In some such cases, the heater may be an
electrically resistive heater (with exposed contacts for connection
to an electrical circuit). In other such cases, the heater may be a
susceptor embedded in the aerosol generating substrate, which is
heated by induction.
[0084] The aerosol generating assembly may additionally comprise a
cooling element and/or a filter. The cooling element, if present,
may act or function to cool gaseous or aerosol components. In some
cases, it may act to cool gaseous components such that they
condense to form an aerosol. It may also act to space the very hot
parts of the apparatus from the user. The filter, if present, may
comprise any suitable filter known in the art such as a cellulose
acetate plug.
[0085] In some cases, the aerosol generating assembly may be a
heat-not-burn device. A heat-not-burn device is disclosed in WO
2015/062983 A2, which is incorporated by reference in its entirety.
In some cases, the aerosol generating assembly may be an electronic
tobacco hybrid device. An electronic tobacco hybrid device is
disclosed in WO 2016/135331 A1, which is incorporated by reference
in its entirety.
[0086] The aerosol generating article or assembly may additionally
comprise ventilation apertures. These may be provided in the
sidewall of the article. In some cases, the ventilation apertures
may be provided in the filter and/or cooling element. These
apertures may allow cool air to be drawn into the article during
use, which can mix with the heated volatilized components thereby
cooling the aerosol.
[0087] The ventilation enhances the generation of visible heated
volatilized components from the article when it is heated in use.
The heated volatilized components are made visible by the process
of cooling the heated volatilized components such that
supersaturation of the heated volatilized components occurs. The
heated volatilized components then undergo droplet formation,
otherwise known as nucleation, and eventually the size of the
aerosol particles of the heated volatilized components increases by
further condensation of the heated volatilized components and by
coagulation of newly formed droplets from the heated volatilized
components.
[0088] In some cases, the ratio of the cool air to the sum of the
heated volatilized components and the cool air, known as the
ventilation ratio, is at least 15%. A ventilation ratio of 15%
enables the heated volatilized components to be made visible by the
method described above. The visibility of the heated volatilized
components enables the user to identify that the volatilized
components have been generated and adds to the sensory experience
of the smoking experience.
[0089] In another example, the ventilation ratio is between 50% and
85% to provide additional cooling to the heated volatilized
components. In some cases, the ventilation ratio may be at least
60% or 65%.
[0090] The assembly may comprise an integrated aerosol generating
article and heater. For example, the integrated heater may be a
combustible or chemical heat source the heats the aerosol
generating substrate, without burning, in use. Alternatively, the
assembly may comprise a heater device into which the article is
inserted in use, wherein the heater is configured to heat but not
burn the aerosol generating substrate.
[0091] Referring to FIGS. 1 and 2, there are shown a partially
cut-away section view and a perspective view of an example of an
aerosol generating article 101. The article 101 is adapted for use
with a device having a power source and a heater. The article 101
of this embodiment is particularly suitable for use with the device
51 shown in FIGS. 5 to 7, described below. In use, the article 101
may be removably inserted into the device shown in FIG. 5 at an
insertion point 20 of the device 51.
[0092] The article 101 of one example is in the form of a
substantially cylindrical rod that includes a body of aerosol
generating material 103 and a filter assembly 105 in the form of a
rod. The aerosol generating material comprises the starch matrix
material described herein. In some embodiments, it may be included
in sheet form. In some embodiments it may be included in the form
of a shredded sheet. In some embodiments, the aerosol generating
material described herein may be incorporated in sheet form and in
shredded form.
[0093] The filter assembly 105 includes three segments, a cooling
segment 107, a filter segment 109 and a mouth end segment 111. The
article 101 has a first end 113, also known as a mouth end or a
proximal end and a second end 115, also known as a distal end. The
body of aerosol generating material 103 is located towards the
distal end 115 of the article 101. In one example, the cooling
segment 107 is located adjacent the body of aerosol generating
material 103 between the body of aerosol generating material 103
and the filter segment 109, such that the cooling segment 107 is in
an abutting relationship with the aerosol generating material 103
and the filter segment 103. In other examples, there may be a
separation between the body of aerosol generating material 103 and
the cooling segment 107 and between the body of aerosol generating
material 103 and the filter segment 109. The filter segment 109 is
located in between the cooling segment 107 and the mouth end
segment 111. The mouth end segment 111 is located towards the
proximal end 113 of the article 101, adjacent the filter segment
109. In one example, the filter segment 109 is in an abutting
relationship with the mouth end segment 111. In one embodiment, the
total length of the filter assembly 105 is between 37 mm and 45 mm,
more preferably, the total length of the filter assembly 105 is 41
mm.
[0094] In one example, the rod of aerosol generating material 103
is between 34 mm and 50 mm in length, suitably between 38 mm and 46
mm in length, suitably 42 mm in length.
[0095] In one example, the total length of the article 101 is
between 71 mm and 95 mm, suitably between 79 mm and 87 mm, suitably
83 mm.
[0096] An axial end of the body of aerosol generating material 103
is visible at the distal end 115 of the article 101. However, in
other embodiments, the distal end 115 of the article 101 may
comprise an end member (not shown) covering the axial end of the
body of aerosol generating material 103.
[0097] The body of aerosol generating material 103 is joined to the
filter assembly 105 by annular tipping paper (not shown), which is
located substantially around the circumference of the filter
assembly 105 to surround the filter assembly 105 and extends
partially along the length of the body of aerosol generating
material 103. In one example, the tipping paper is made of 58 GSM
standard tipping base paper. In one example the tipping paper has a
length of between 42 mm and 50 mm, suitably of 46 mm.
[0098] In one example, the cooling segment 107 is an annular tube
and is located around and defines an air gap within the cooling
segment. The air gap provides a chamber for heated volatilized
components generated from the body of aerosol generating material
103 to flow.
[0099] The cooling segment 107 is hollow to provide a chamber for
aerosol accumulation yet rigid enough to withstand axial
compressive forces and bending moments that might arise during
manufacture and whilst the article 101 is in use during insertion
into the device 51. In one example, the thickness of the wall of
the cooling segment 107 is approximately 0.29 mm.
[0100] The cooling segment 107 provides a physical displacement
between the aerosol generating material 103 and the filter segment
109. The physical displacement provided by the cooling segment 107
will provide a thermal gradient across the length of the cooling
segment 107. In one example the cooling segment 107 is configured
to provide a temperature differential of at least 40 degrees
Celsius between a heated volatilized component entering a first end
of the cooling segment 107 and a heated volatilized component
exiting a second end of the cooling segment 107. In one example the
cooling segment 107 is configured to provide a temperature
differential of at least 60 degrees Celsius between a heated
volatilized component entering a first end of the cooling segment
107 and a heated volatilized component exiting a second end of the
cooling segment 107. This temperature differential across the
length of the cooling element 107 protects the temperature
sensitive filter segment 109 from the high temperatures of the
aerosol generating material 103 when it is heated by the device 51.
If the physical displacement was not provided between the filter
segment 109 and the body of aerosol generating material 103 and the
heating elements of the device 51, then the temperature sensitive
filter segment may 109 become damaged in use, so it would not
perform its required functions as effectively.
[0101] In one example the length of the cooling segment 107 is at
least 15 mm. In one example, the length of the cooling segment 107
is between 20 mm and 30 mm, more particularly 23 mm to 27 mm, more
particularly 25 mm to 27 mm, suitably 25 mm.
[0102] The cooling segment 107 is made of paper, which means that
it is comprised of a material that does not generate compounds of
concern, for example, toxic compounds when in use adjacent to the
heater of the device 51. In one example, the cooling segment 107 is
manufactured from a spirally wound paper tube which provides a
hollow internal chamber yet maintains mechanical rigidity. Spirally
wound paper tubes are able to meet the tight dimensional accuracy
requirements of high-speed manufacturing processes with respect to
tube length, outer diameter, roundness and straightness.
[0103] In another example, the cooling segment 107 is a recess
created from stiff plug wrap or tipping paper. The stiff plug wrap
or tipping paper is manufactured to have a rigidity that is
sufficient to withstand the axial compressive forces and bending
moments that might arise during manufacture and whilst the article
101 is in use during insertion into the device 51.
[0104] The filter segment 109 may be formed of any filter material
sufficient to remove one or more volatilized compounds from heated
volatilized components from the aerosol generating material. In one
example the filter segment 109 is made of a mono-acetate material,
such as cellulose acetate. The filter segment 109 provides cooling
and irritation-reduction from the heated volatilized components
without depleting the quantity of the heated volatilized components
to an unsatisfactory level for a user.
[0105] In some embodiments, a capsule (not illustrated) may be
provided in filter segment 109. It may be disposed substantially
centrally in the filter segment 109, both across the filter segment
109 diameter and along the filter segment 109 length. In other
cases, it may be offset in one or more dimension. The capsule may
in some cases, where present, contain a volatile component such as
a flavorant or aerosol generating agent.
[0106] The density of the cellulose acetate tow material of the
filter segment 109 controls the pressure drop across the filter
segment 109, which in turn controls the draw resistance of the
article 101. Therefore the selection of the material of the filter
segment 109 is important in controlling the resistance to draw of
the article 101. In addition, the filter segment performs a
filtration function in the article 101.
[0107] In one example, the filter segment 109 is made of a 8Y15
grade of filter tow material, which provides a filtration effect on
the heated volatilized material, whilst also reducing the size of
condensed aerosol droplets which result from the heated volatilized
material.
[0108] The presence of the filter segment 109 provides an
insulating effect by providing further cooling to the heated
volatilized components that exit the cooling segment 107. This
further cooling effect reduces the contact temperature of the
user's lips on the surface of the filter segment 109.
[0109] In one example, the filter segment 109 is between 6 mm to 10
mm in length, suitably 8 mm.
[0110] The mouth end segment 111 is an annular tube and is located
around and defines an air gap within the mouth end segment 111. The
air gap provides a chamber for heated volatilized components that
flow from the filter segment 109. The mouth end segment 111 is
hollow to provide a chamber for aerosol accumulation yet rigid
enough to withstand axial compressive forces and bending moments
that might arise during manufacture and whilst the article is in
use during insertion into the device 51. In one example, the
thickness of the wall of the mouth end segment 111 is approximately
0.29 mm. In one example, the length of the mouth end segment 111 is
between 6 mm to 10 mm, suitably 8 mm.
[0111] The mouth end segment 111 may be manufactured from a
spirally wound paper tube which provides a hollow internal chamber
yet maintains critical mechanical rigidity. Spirally wound paper
tubes are able to meet the tight dimensional accuracy requirements
of high-speed manufacturing processes with respect to tube length,
outer diameter, roundness and straightness.
[0112] The mouth end segment 111 provides the function of
preventing any liquid condensate that accumulates at the exit of
the filter segment 109 from coming into direct contact with a
user.
[0113] It should be appreciated that, in one example, the mouth end
segment 111 and the cooling segment 107 may be formed of a single
tube and the filter segment 109 is located within that tube
separating the mouth end segment 111 and the cooling segment
107.
[0114] Referring to FIGS. 3 and 4, there are shown a partially
cut-away section and perspective views of an example of an article
301. The reference signs shown in FIGS. 3 and 4 are equivalent to
the reference signs shown in FIGS. 1 and 2, but with an increment
of 200.
[0115] In the example of the article 301 shown in FIGS. 3 and 4, a
ventilation region 317 is provided in the article 301 to enable air
to flow into the interior of the article 301 from the exterior of
the article 301. In one example the ventilation region 317 takes
the form of one or more ventilation holes 317 formed through the
outer layer of the article 301. The ventilation holes may be
located in the cooling segment 307 to aid with the cooling of the
article 301. In one example, the ventilation region 317 comprises
one or more rows of holes, and preferably, each row of holes is
arranged circumferentially around the article 301 in a
cross-section that is substantially perpendicular to a longitudinal
axis of the article 301.
[0116] In one example, there are between one to four rows of
ventilation holes to provide ventilation for the article 301. Each
row of ventilation holes may have between 12 to 36 ventilation
holes 317. The ventilation holes 317 may, for example, be between
100 to 500 .mu.m in diameter. In one example, an axial separation
between rows of ventilation holes 317 is between 0.25 mm and 0.75
mm, suitably 0.5 mm.
[0117] In one example, the ventilation holes 317 are of uniform
size. In another example, the ventilation holes 317 vary in size.
The ventilation holes can be made using any suitable technique, for
example, one or more of the following techniques: laser technology,
mechanical perforation of the cooling segment 307 or
pre-perforation of the cooling segment 307 before it is formed into
the article 301. The ventilation holes 317 are positioned so as to
provide effective cooling to the article 301.
[0118] In one example, the rows of ventilation holes 317 are
located at least 11 mm from the proximal end 313 of the article,
suitably between 17 mm and 20 mm from the proximal end 313 of the
article 301. The location of the ventilation holes 317 is
positioned such that user does not block the ventilation holes 317
when the article 301 is in use.
[0119] Providing the rows of ventilation holes between 17 mm and 20
mm from the proximal end 313 of the article 301 enables the
ventilation holes 317 to be located outside of the device 51, when
the article 301 is fully inserted in the device 51, as can be seen
in FIGS. 6 and 7. By locating the ventilation holes outside of the
device, non-heated air is able to enter the article 301 through the
ventilation holes from outside the device 51 to aid with the
cooling of the article 301.
[0120] The length of the cooling segment 307 is such that the
cooling segment 307 will be partially inserted into the device 51,
when the article 301 is fully inserted into the device 51. The
length of the cooling segment 307 provides a first function of
providing a physical gap between the heater arrangement of the
device 51 and the heat sensitive filter arrangement 309, and a
second function of enabling the ventilation holes 317 to be located
in the cooling segment, whilst also being located outside of the
device 51, when the article 301 is fully inserted into the device
51. As can be seen from FIGS. 6 and 7, the majority of the cooling
element 307 is located within the device 51. However, there is a
portion of the cooling element 307 that extends out of the device
51. It is in this portion of the cooling element 307 that extends
out of the device 51 in which the ventilation holes 317 are
located.
[0121] Referring now to FIGS. 5 to 7 in more detail, there is shown
an example of a device 51 arranged to heat aerosol generating
material to volatilize at least one component of said aerosol
generating material, typically to form an aerosol which can be
inhaled. The device 51 is a heating device which releases compounds
by heating, but not burning, the aerosol generating material.
[0122] A first end 53 is sometimes referred to herein as the mouth
or proximal end 53 of the device 51 and a second end 55 is
sometimes referred to herein as the distal end 55 of the device 51.
The device 51 has an on/off button 57 to allow the device 51 as a
whole to be switched on and off as desired by a user.
[0123] The device 51 comprises a housing 59 for locating and
protecting various internal components of the device 51. In the
example shown, the housing 59 comprises a uni-body sleeve 11 that
encompasses the perimeter of the device 51, capped with a top panel
17 which defines generally the `top` of the device 51 and a bottom
panel 19 which defines generally the `bottom` of the device 51. In
another example the housing comprises a front panel, a rear panel
and a pair of opposite side panels in addition to the top panel 17
and the bottom panel 19.
[0124] The top panel 17 and/or the bottom panel 19 may be removably
fixed to the uni-body sleeve 11, to permit easy access to the
interior of the device 51, or may be "permanently" fixed to the
uni-body sleeve 11, for example to deter a user from accessing the
interior of the device 51. In an example, the panels 17 and 19 are
made of a plastics material, including for example glass-filled
nylon formed by injection molding, and the uni-body sleeve 11 is
made of aluminum, though other materials and other manufacturing
processes may be used.
[0125] The top panel 17 of the device 51 has an opening 20 at the
mouth end 53 of the device 51 through which, in use, the article
101, 301 including the aerosol generating material may be inserted
into the device 51 and removed from the device 51 by a user.
[0126] The housing 59 has located or fixed therein a heater
arrangement 23, control circuitry 25 and a power source 27. In this
example, the heater arrangement 23, the control circuitry 25 and
the power source 27 are laterally adjacent (that is, adjacent when
viewed from an end), with the control circuitry 25 being located
generally between the heater arrangement 23 and the power source
27, though other locations are possible.
[0127] The control circuitry 25 may include a controller, such as a
microprocessor arrangement, configured and arranged to control the
heating of the aerosol generating material in the article 101, 301
as discussed further below.
[0128] The power source 27 may be for example a battery, which may
be a rechargeable battery or a non-rechargeable battery. Examples
of suitable batteries include for example a lithium-ion battery, a
nickel battery (such as a nickel-cadmium battery), an alkaline
battery and/or the like. The battery 27 is electrically coupled to
the heater arrangement 23 to supply electrical power when required
and under control of the control circuitry 25 to heat the aerosol
generating material in the article (as discussed, to volatilize the
aerosol generating material without causing the aerosol generating
material to burn).
[0129] An advantage of locating the power source 27 laterally
adjacent to the heater arrangement 23 is that a physically large
power source 25 may be used without causing the device 51 as a
whole to be unduly lengthy. As will be understood, in general a
physically large power source 25 has a higher capacity (that is,
the total electrical energy that can be supplied, often measured in
Amp-hours or the like) and thus the battery life for the device 51
can be longer.
[0130] In one example, the heater arrangement 23 is generally in
the form of a hollow cylindrical tube, having a hollow interior
heating chamber 29 into which the article 101, 301 comprising the
aerosol generating material is inserted for heating in use.
Different arrangements for the heater arrangement 23 are possible.
For example, the heater arrangement 23 may comprise a single
heating element or may be formed of plural heating elements aligned
along the longitudinal axis of the heater arrangement 23. The or
each heating element may be annular or tubular, or at least
part-annular or part-tubular around its circumference. In an
example, the or each heating element may be a thin film heater. In
another example, the or each heating element may be made of a
ceramics material. Examples of suitable ceramics materials include
alumina and aluminum nitride and silicon nitride ceramics, which
may be laminated and sintered. Other heating arrangements are
possible, including for example inductive heating, infrared heater
elements, which heat by emitting infrared radiation, or resistive
heating elements formed by for example a resistive electrical
winding.
[0131] In one particular example, the heater arrangement 23 is
supported by a stainless steel support tube and comprises a
polyimide heating element. The heater arrangement 23 is dimensioned
so that substantially the whole of the body of aerosol generating
material 103, 303 of the article 101, 301 is inserted into the
heater arrangement 23 when the article 101, 301 is inserted into
the device 51.
[0132] The or each heating element may be arranged so that selected
zones of the aerosol generating material can be independently
heated, for example in turn (over time, as discussed above) or
together (simultaneously) as desired.
[0133] The heater arrangement 23 in this example is surrounded
along at least part of its length by a thermal insulator 31. The
insulator 31 helps to reduce heat passing from the heater
arrangement 23 to the exterior of the device 51. This helps to keep
down the power requirements for the heater arrangement 23 as it
reduces heat losses generally. The insulator 31 also helps to keep
the exterior of the device 51 cool during operation of the heater
arrangement 23. In one example, the insulator 31 may be a
double-walled sleeve which provides a low pressure region between
the two walls of the sleeve. That is, the insulator 31 may be for
example a "vacuum" tube, i.e. a tube that has been at least
partially evacuated so as to minimize heat transfer by conduction
and/or convection. Other arrangements for the insulator 31 are
possible, including using heat insulating materials, including for
example a suitable foam-type material, in addition to or instead of
a double-walled sleeve.
[0134] The housing 59 may further comprises various internal
support structures 37 for supporting all internal components, as
well as the heating arrangement 23.
[0135] The device 51 further comprises a collar 33 which extends
around and projects from the opening 20 into the interior of the
housing 59 and a generally tubular chamber 35 which is located
between the collar 33 and one end of the vacuum sleeve 31. The
chamber 35 further comprises a cooling structure 35f, which in this
example, comprises a plurality of cooling fins 35f spaced apart
along the outer surface of the chamber 35, and each arranged
circumferentially around outer surface of the chamber 35. There is
an air gap 36 between the hollow chamber 35 and the article 101,
301 when it is inserted in the device 51 over at least part of the
length of the hollow chamber 35. The air gap 36 is around all of
the circumference of the article 101, 301 over at least part of the
cooling segment 307.
[0136] The collar 33 comprises a plurality of ridges 60 arranged
circumferentially around the periphery of the opening 20 and which
project into the opening 20. The ridges 60 take up space within the
opening 20 such that the open span of the opening 20 at the
locations of the ridges 60 is less than the open span of the
opening 20 at the locations without the ridges 60. The ridges 60
are configured to engage with an article 101, 301 inserted into the
device to assist in securing it within the device 51. Open spaces
(not shown in the Figures) defined by adjacent pairs of ridges 60
and the article 101, 301 form ventilation paths around the exterior
of the article 101, 301. These ventilation paths allow hot vapors
that have escaped from the article 101, 301 to exit the device 51
and allow cooling air to flow into the device 51 around the article
101, 301 in the air gap 36.
[0137] In operation, the article 101, 301 is removably inserted
into an insertion point 20 of the device 51, as shown in FIGS. 5 to
7. Referring particularly to FIG. 6, in one example, the body of
aerosol generating material 103, 303, which is located towards the
distal end 115, 315 of the article 101, 301, is entirely received
within the heater arrangement 23 of the device 51.
[0138] The proximal end 113, 313 of the article 101, 301 extends
from the device 51 and acts as a mouthpiece assembly for a
user.
[0139] In operation, the heater arrangement 23 will heat the
article 101, 301 to volatilize at least one component of the
aerosol generating material from the body of aerosol generating
material 103, 303.
[0140] The primary flow path for the heated volatilized components
from the body of aerosol generating material 103, 303 is axially
through the article 101, 301, through the chamber inside the
cooling segment 107, 307, through the filter segment 109, 309,
through the mouth end segment 111, 313 to the user. In one example,
the temperature of the heated volatilized components that are
generated from the body of aerosol generating material is between
60.degree. C. and 250.degree. C., which may be above the acceptable
inhalation temperature for a user. As the heated volatilized
component travels through the cooling segment 107, 307, it will
cool and some volatilized components will condense on the inner
surface of the cooling segment 107, 307.
[0141] In the examples of the article 301 shown in FIGS. 3 and 4,
cool air will be able to enter the cooling segment 307 via the
ventilation holes 317 formed in the cooling segment 307. This cool
air will mix with the heated volatilized components to provide
additional cooling to the heated volatilized components.
[0142] A third aspect of the invention provides starch matrix
material comprising; [0143] a plasticizer wherein the amount of
plasticizer is from about 5% to 70% by weight of the starch; and
[0144] a plant-derived flavor or aroma component.
[0145] Features described herein in relation to the "aerosol
generating material" are hereby explicating disclosed in
combination with the third aspect of the invention.
[0146] Suitably, the plant-derived flavor or aroma component
comprises a tobacco material, such as a tobacco extract.
[0147] Suitably, the plant-derived flavor or aroma component may be
a powdered component, added in an amount 40% to 300% by weight of
the starch.
[0148] The invention also provides a method of making an aerosol
generating article according to the first aspect, the method
comprising;
[0149] (i) mixing the constituent parts of the aerosol generating
material in a slurry, heating and stirring the slurry to effect
gelation, casting the gel and drying by heating to form the aerosol
generating material; and
[0150] (ii) incorporating the aerosol generating material in an
aerosol generating article.
[0151] In some cases, the heating and stirring step may involve
heating to around 70-100.degree. C., suitably 85.degree. C. for up
to about 20 minutes. The drying step may involve heating around
30-70.degree. C., suitably 50.degree. C., for 1-5 hours, suitably
around 3 hours.
[0152] The method may include an additional step comprising
shredding the aerosol generating material, before it is
incorporated into an aerosol generating article.
[0153] The invention also provides a slurry comprising: [0154] a
starch; [0155] a plasticizer wherein the amount of plasticizer is
from about 5% to 70% by weight of the starch; and [0156] a
plant-derived flavor or aroma component; and [0157] water.
[0158] Suitably, the weight ratio of water to the total weight of
the other ingredients is between about 10:1 and 20:1.
[0159] In some examples, the slurry has a viscosity of from about
10 to about 20 Pas at 46.5.degree. C., such as from about 14 to
about 16 Pas at 46.5.degree. C.
[0160] The invention also provides a slurry comprising: [0161] a
starch; [0162] a plasticizer, wherein the amount of plasticizer is
from about 5% to 70% by weight of the starch; [0163] a powdered
tobacco material having a mean particle diameter of less than about
250 .mu.m, wherein the amount of powdered tobacco material is from
about 40% to 300% by weight of the starch; [0164] water, wherein
the weight ratio of water to the total weight of the other
ingredients is between about 10:1 and 20:1.
[0165] The invention also provides a slurry comprising [0166] a
starch; [0167] a plasticizer, wherein the amount of plasticizer is
from about 5% to 70% by weight of the starch; [0168] a aqueous
tobacco extract, wherein the weight ratio of the aqueous tobacco
extract to the total weight of the other ingredients is between
about 10:1 and 20:1.
[0169] Further aspects of the invention include; [0170] (iii) a
wrapper for a smoking article or aerosol generating article,
wherein the wrapper comprises a starch matrix and a plasticizer,
wherein the amount of plasticizer is from about 5% to 30% by weight
of the starch; and [0171] (iv) a filter for a smoking article or
aerosol generating article, the filter comprising a starch matrix
and a plasticizer, wherein the amount of plasticizer is from about
5% to 15% by weight of the starch.
[0172] The inventors have established that these starch matrix
materials find application as filters and wrappers, in addition to
as an aerosol generating material.
[0173] The invention also provides articles including the above
wrapper and/or filter.
EXAMPLES
Example 1
[0174] A starch matrix film was prepared as follows:
[0175] 1000 mg of potato starch, 300 mg glycerol and 20 mL water
were added to a 50mL beaker. The slurry was stirred using a
stirring bar and the mixture was heated to 85.degree. C. under
vigorous stirring vigorously for 10 min. Thickening (or gelation)
of the mixture was observed.
[0176] The gel was cast onto a PTFE sheet. (The gel is very polar
so it will stick strongly to glass or metal.) The material was
dried for 2 hrs @ 50.degree. C. to generate a film having a
thickness of 4 mm.
Example 2
[0177] In another example, a starch matrix film was made using the
process of example 1, with the addition of 500-2000 mg of tobacco
powder (particle size 200 .mu.m) to the mixture prior to
stirring.
Example 3
[0178] In another example, a starch matrix film was made using the
process of example 1, except that the water was replaced with 20 mL
of aqueous tobacco extract (obtained by extraction of ground
Virginia tobacco with deionized water) and 450 mg of glycerol was
used (rather than 300 mg).
Testing
[0179] The materials of each example will be heated, without
burning, in a simulated puff regime (heating to 250.degree. C., 2
second puffs taken every 30 seconds under a 1.65 L/min
airflow).
Definitions
[0180] The active substance as used herein may be a physiologically
active material, which is a material intended to achieve or enhance
a physiological response. The active substance may for example be
selected from nutraceuticals, nootropics, psychoactives. The active
substance may be naturally occurring or synthetically obtained. The
active substance may comprise for example nicotine, caffeine,
taurine, theine, vitamins such as B6 or B12 or C, melatonin,
cannabinoids, or constituents, derivatives, or combinations
thereof. The active substance may comprise one or more
constituents, derivatives or extracts of tobacco, cannabis or
another botanical.
[0181] In some embodiments, the active substance comprises
nicotine.
[0182] In some embodiments, the active substance comprises
caffeine, melatonin or vitamin B12.
[0183] As noted herein, the active substance may comprise one or
more constituents, derivatives or extracts of cannabis, such as one
or more cannabinoids or terpenes.
[0184] Cannabinoids are a class of natural or synthetic chemical
compounds which act on cannabinoid receptors (i.e., CB1 and CB2) in
cells that repress neurotransmitter release in the brain.
Cannabinoids may be naturally occurring (phytocannabinoids) from
plants such as cannabis, from animals (endocannabinoids), or
artificially manufactured (synthetic cannabinoids). Cannabis
species express at least 85 different phytocannabinoids, and are
divided into subclasses, including cannabigerols, cannabichromenes,
cannabidiols, tetrahydrocannabinols, cannabinols and
cannabinodiols, and other cannabinoids. Cannabinoids found in
cannabis include, without limitation: cannabigerol (CBG),
cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol
(THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL),
cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin
(CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV),
cannabigerol monomethyl ether (CBGM), cannabinerolic acid,
cannabidiolic acid (CBDA), Cannabinol propyl variant (CBNV),
cannabitriol (CBO), tetrahydrocannabmolic acid (THCA), and
tetrahydrocannabivarinic acid (THCV A).
[0185] As noted herein, the active substance may comprise or be
derived from one or more botanicals or constituents, derivatives or
extracts thereof. As used herein, the term "botanical" includes any
material derived from plants including, but not limited to,
extracts, leaves, bark, fibres fibers, stems, roots, seeds,
flowers, fruits, pollen, husk, shells or the like. Alternatively,
the material may comprise an active compound naturally existing in
a botanical, obtained synthetically. The material may be in the
form of liquid, gas, solid, powder, dust, crushed particles,
granules, pellets, shreds, strips, sheets, or the like. Example
botanicals are tobacco, eucalyptus, star anise, hemp, cocoa,
cannabis, fennel, lemongrass, peppermint, spearmint, rooibos,
chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel,
licorice (liquorice), matcha, mate, orange skin, papaya, rose,
sage, tea such as green tea or black tea, thyme, clove, cinnamon,
coffee, aniseed (anise), basil, bay leaves, cardamom, coriander,
cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon
peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak
plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange
blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram,
olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon,
geranium, mulberry, ginseng, theanine, theacrine, maca,
ashwagandha, damiana, guarana, chlorophyll, baobab or any
combination thereof. The mint may be chosen from the following mint
varieties: Mentha arvensis, Mentha c.v., Mentha niliaca, Mentha
piperita, Mentha piperita citrata c.v., Mentha piperita c.v.,
Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha
suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and
Mentha suaveolens.
[0186] In some embodiments, the botanical is selected from
eucalyptus, star anise, cocoa and hemp.
[0187] In some embodiments, the botanical is selected from rooibos
and fennel.
[0188] As used herein, the terms "flavor" and "flavorant" refer to
materials which, where local regulations permit, may be used to
create a desired taste, aroma or other somatosensorial sensation in
a product for adult consumers. They may include naturally occurring
flavor materials, botanicals, extracts of botanicals, synthetically
obtained materials, or combinations thereof (e.g., tobacco,
cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white
bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha,
menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian
spices, Asian spices, herb, wintergreen, cherry, berry, red berry,
cranberry, peach, apple, orange, mango, clementine, lemon, lime,
tropical fruit, papaya, rhubarb, grape, durian, dragon fruit,
cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon,
scotch, whiskey, gin, tequila, rum, spearmint, peppermint,
lavender, aloe vera, cardamom, celery, cascarilla, nutmeg,
sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine,
honey essence, rose oil, vanilla, lemon oil, orange oil, orange
blossom, cherry blossom, cassia, caraway, cognac, jasmine,
ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander,
coffee, hemp, a mint oil from any species of the genus Mentha,
eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo
biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such
as green tea or black tea, thyme, juniper, elderflower, basil, bay
leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel,
mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian,
pimento, mace, damien, marjoram, olive, lemon balm, lemon basil,
chive, carvi, verbena, tarragon, limonene, thymol, camphene),
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, liquid such
as an oil, solid such as a powder, or gas.
[0189] The flavor may suitably comprise one or more mint-flavors
suitably a mint oil from any species of the genus Mentha. The
flavor may suitably comprise, consist essentially of or consist of
menthol.
[0190] In some embodiments, the flavor comprises menthol, spearmint
and/or peppermint.
[0191] In some embodiments, the flavor comprises flavor components
of cucumber, blueberry, citrus fruits and/or redberry.
[0192] In some embodiments, the flavor comprises eugenol.
[0193] In some embodiments, the flavor comprises flavor components
extracted from tobacco.
[0194] In some embodiments, the flavor comprises flavor components
extracted from cannabis.
[0195] In some embodiments, the flavor may comprise a sensate,
which is intended to achieve a somatosensorial sensation which are
usually chemically induced and perceived by the stimulation of the
fifth cranial nerve (trigeminal nerve), in addition to or in place
of aroma or taste nerves, and these may include agents providing
heating, cooling, tingling, numbing effect. A suitable heat effect
agent may be, but is not limited to, vanillyl ethyl ether and a
suitable cooling agent may be, but not limited to eucalyptol,
WS-3.
[0196] As used herein, the term "aerosol generating agent" refers
to an agent that promotes the generation of an aerosol. An aerosol
generating agent may promote the generation of an aerosol by
promoting an initial vaporization and/or the condensation of a gas
to an inhalable solid and/or liquid aerosol.
[0197] As used herein, the term "tobacco material" refers to any
material comprising tobacco or derivatives therefore. The term
"tobacco material" may include one or more of tobacco, tobacco
derivatives, expanded tobacco, reconstituted tobacco or tobacco
substitutes. The tobacco material may comprise one or more of
ground tobacco, tobacco fiber, cut tobacco, extruded tobacco,
tobacco stem, reconstituted tobacco and/or tobacco extract.
[0198] The tobacco used to produce tobacco material may be any
suitable tobacco, such as single grades or blends, cut rag or whole
leaf, including Virginia and/or Burley and/or Oriental. It may also
be tobacco particle `fines` or dust, expanded tobacco, stems,
expanded stems, and other processed stem materials, such as cut
rolled stems. The tobacco material may be a ground tobacco or a
reconstituted tobacco material. The reconstituted tobacco material
may comprise tobacco fibers, and may be formed by casting, a
Fourdrinier-based paper making-type approach with back addition of
tobacco extract, or by extrusion.
[0199] All percentages by weight described herein (denoted wt %)
are calculated on a dry weight basis, unless explicitly stated
otherwise. All weight ratios are also calculated on a dry weight
basis. A weight quoted on a dry weight basis refers to the whole of
the extract or slurry or material, other than the water, and may
include components which by themselves are liquid at room
temperature and pressure, such as glycerol. Conversely, a weight
percentage quoted on a wet weight basis refers to all components,
including water.
[0200] For the avoidance of doubt, where in this specification the
term "comprises" is used in defining the invention or features of
the invention, embodiments are also disclosed in which the
invention or feature can be defined using the terms "consists
essentially of" or "consists of" in place of "comprises". Reference
to a material "comprising" certain features means that those
features are included in, contained in, or held within the
material.
[0201] The above embodiments are to be understood as illustrative
examples of the invention. It is to be understood that any feature
described in relation to any one embodiment may be used alone, or
in combination with other features described, and may also be used
in combination with one or more features of any other of the
embodiments, or any combination of any other of the embodiments.
Furthermore, equivalents and modifications not described above may
also be employed without departing from the scope of the invention,
which is defined in the accompanying claims.
* * * * *