Aerosol Generating Article

Abstract

An aerosol generating article (10) for a non-combustion heating aerosol generating device comprising an aerosol generating substrate and a mouthpiece downstream of the aerosol generating substrate, wherein the aerosol generating substrate is contained in a wrapper and in the form of a foam comprising an aerosol forming agent, a source of nicotine and a non-tobacco flavouring agent, wherein the mouthpiece comprises a filter (16) and a spacing and/or cooling element (14) is provided between the aerosol generating substrate and the filter (16), and wherein the aerosol generating substrate comprises between 0.1 and 10 wt. % nicotine in dry basis of the aerosol generating substrate.

Description

TECHNICAL FIELD

The invention relates to an aerosol generating article for a non-combustion heating aerosol generating device.

TECHNICAL BACKGROUND

Aerosol generating devices such as vaporizers have become popular as a replacement for conventional smoking articles. In such devices, an aerosol is heated for example by means of an electric heater. In this context, it is, firstly, desirable that the users can experience vaping in a manner which is as close as possible to the experience made with normal cigarettes. Secondly, leakage of the aerosol generating substrate, such as a liquid, is to be prevented as far as possible.

PRIOR ART

Leakage can be prevented by aerosol generating substrates which are provided as a mousse such as those disclosed by WO 2018/122 375 A1 and WO 2020/002607 A1. WO 2020 254582 A1, 2021/083844 A1, WO 2021/094453 A1 and WO 2021/094365 A1 are related to such mousses and hot pressed tobacco substrates respectively. WO 2020/127261 A1 teaches an extrusion for forming a tobacco mousse, and WO 2021 105449 A1 is related to a consumable for an aerosol generating device comprising at least two aerosol generating materials of a different composition, each comprising an amorphous solid formed of a gelling agent.

SUMMARY OF THE INVENTION

Despite the above-mentioned teachings, there is still a need to provide an aerosol generating article which is improved with regard to the flavour release and/or vapor delivery.

This is achieved by the subject-matter of claim 1.

Accordingly, the article comprises an aerosol generating substrate and a mouthpiece downstream of the aerosol generating substrate, which is contained in a wrapper and is in the form of a foam comprising an aerosol forming agent, a source of nicotine and a non-tobacco flavouring agent. Further, the mouthpiece comprises a filter and a spacing and/or cooling element is provided between the aerosol generating substrate and the filter, wherein the aerosol generating substrate comprises between 0.1 and 10 wt. % nicotine in dry basis of the aerosol generating substrate. The wrapper can for example be made from a cigarette paper and can be metallized or not. In either case, it can be designed to avoid scorching of the foam, which can also be called an e-mousse as it is a mousse used with an electronic cigarette.

Providing the aerosol generating substrate in the form of a foam provides the significant advantage that leakage can be prevented, as the foam is significantly more stable than a liquid and does not leak as easily as a liquid may. Moreover, the amount of foam can be adjusted in a manner which corresponds to the session time, which users are used to, i.e. to the session time of a regular cigarette.

Moreover, it has been found that any desirable volatiles of the aerosol, such as nicotine and/or flavouring can easily be provided in a foam and can be released to a controllable concentration and/or intensity. In this context, the amount of nicotine can also be varied which allows the users to control their nicotine uptake. In this context, a source of nicotine means any substance capable of releasing nicotine when heated. Such a substance does not necessarily have to be tobacco, but the nicotine can be extracted from tobacco and dosed in the foam.

As regards the filter provided in the mouthpiece, this can be adapted to provide a relatively low, in any case, acceptable pressure drop, so that flavouring intensity and nicotine yield remain optimal. Additionally, the presence of the spacing and/or cooling element will, firstly, cool the generated aerosol, so that aerosol having an uncomfortably high temperature is prevented from entering the user's mouth. Moreover, by means of the spacing element the article according to the present invention can be provided with a size adapted to well-established aerosol generating devices, with which the article can be used. Due to the fact that the article described herein can be used with present aerosol generating devices, the users have the advantage that a single device is sufficient and only one device has to be maintained.

Preferred embodiments are described in the further claims.

Whereas the aerosol generating article can still have tobacco material making it somewhat more similar to a normal cigarette, it is currently preferred to provide the aerosol generating substrate free of tobacco material.

In order to provide a stable foam which is, as a consequence, particularly unlikely to leak, the aerosol generating substrate preferably comprises a foam forming agent and/or a foam stabilizing agent.

In order to provide reasonable nicotine levels, the amount of nicotine in dry basis of the aerosol generating substrate is preferably between 0.1 and 4 wt. %

In first tests, an amount of at least 30 wt. %, preferably at least 40 wt. % and most preferred at least 50 wt. % of the aerosol generating substrate have proven beneficial with regard to the aerosol forming agent.

In particular, an amount of 60 to 70 wt. % is currently preferred.

Preferred aerosol forming agents are selected from a group comprising: glycerol, glycol derivatives, sebacate esters, and/or mixtures thereof, without being limited thereto.

In particular, the aerosol forming agent is a combination of glycerol and propylene glycol, preferably in a ratio of 10%:90% to 90%:10%, more preferably 40%:60% to 60%:40%, most preferably 50%:50%.

Small amount of water and/or an acid and/or an ester, e.g. diacetin, may be contained into the aerosol generating substrate. In preferred example, the foam may comprise water in an amount of 0-15 wt. % of the weight of the foam, e.g., 9-10 wt. %.

Preferred foam forming agents are selected from the group consisting of agar, gellan gum, lecithin, polyglycerol esters of fatty acids, glycerol esters of fatty acids, sorbitan esters of fatty acids, and/or mixtures thereof, without being limited thereto.

The amount of foam forming agent is preferably comprised between 1 and 15 wt. % of the foam, more preferably between 2 and 10 wt. %, most preferably between 3 and 8 wt. % of the foam.

Preferred foam stabilizing agents are selected from the group consisting of cellulose gum, hydroxyalkylated carbohydrates, derivatives thereof, and mixture thereof and/or comprise cellulose gum, in particular carboxymethylcellulose (CMC) or derivatives thereof (also referred as “binder” in the present application) and/or cellulose fiber. Cellulose fibre as the foam stabilizing agent is preferably present in an amount between 5 wt. % and 15 wt. % of the foam. Derivatives of CMC may be with salts, preferably alkali metal salts such as sodium and/or potassium salts. The amount of foam stabilizing agent is preferably comprised between 10 and 30 wt. % of the foam, preferably between 12 and 28 wt. %, most preferably between 15 and 25 wt. % of the foam. In a preferred example, the foam stabilizing agent comprises a ratio of between 1:0 and 1:2, more preferably 1:0 to 1:1.1 of cellulose gum (more preferably CMC) to cellulose fibre in the foam.

Preferred non-tobacco flavouring agent are selected amongst the list of: menthol, natural and/or artificial plant flavour (e.g., peppermint, berry, fruit, root or nut), animal, enzymatic or microbiological origin flavour, sweet-like, alcoholic or dessert-like flavour (e.g. chocolate, cookie dough, peanut butter, carrot cake, marshmallow, butter popcorn, prosecco, red wine, rum, jelly bean, Guinness, bourbon, honey, toffee, praline, butterfinger, brown bread etc.) and combinations thereof. As regards the amount of flavouring agent, it is currently preferred to have this with 0.2 to 18 wt. % and preferably 0.6 to 13 wt. % of the foam.

As regards the form of the aerosol generating substrate, the following are conceivable:

• • a hollow tube comprising at least one outlet for air to communicate from outside to the inside of the hollow tube, a cylindrical rod, a cylindrical rod comprising a plurality of longitudinal through-passages or channels, a group of discrete pieces such as beads, in which a cylindrical rod is easiest to manufacture, and a hollow tube leads to the advantage that the heat flow through the hollow can extract more flavour and nicotine as compared to heat flowing through a cylindrical rod, in which the foam or mousse is essentially a single semi-solid element. The effect of allowing more flavour and nicotine to be extracted from the foam is further enhanced by a plurality of longitudinal through-passages, channels or holes essentially extending through the entire substrate, which can also be called a plug. This effect can also be achieved by providing the aerosol generating substrate in the form of plural discrete pieces, such as beads or small elements, into which the foam or mousse is fragmented. These elements can have essentially the same or different shapes and/or sizes.

When the spacing and/or cooling element is a hollow paper tube, this contributes to compostability of the article as a whole. This also applies to the preferred measure of providing the article with a paper filter.

As regards the length of the spacing and/or cooling element, 10 to 25 and preferably 18 to 22 mm are currently preferred.

Whereas the aerosol generating substrate can have any appropriate extension, it will keep the article described herein compact, when the aerosol generating substrate extends from the upstream end towards the downstream end of the article. A preferred total length of the article is also between 50 mm and 70 mm, more preferably between 55 mm and 65 mm, even more preferably 58 mm to 62 mm; wherein the aerosol generating substrate is preferably about 15 mm to 25 mm and the filter is preferably about 15 mm to 25 mm.

The filter may be a paper filter or a filament tow filter. A paper filter may be a wrapped gathered sheet of paper. A filament tow filter may be a cellulose acetate filter. In order to provide a comfortable vaping experience, in particular to not prejudice flavour intensity and nicotine release, the filter has a pressure drop preferably less than 5, more preferably less than 3 and most preferred equal to or less than 2.5 mm H2O/mm are advantageous. The highest of these values allows an acetate filter to be used, and a paper filter can achieve the lower values. The pressure drop is determined under standard conditions defined under standard conditions defined by Coresta Recommended Method No. 41 (2007) and Coresta Guide No. 4 (2019).

In this context, paper sheet of the paper filter with a basis weight of 20 to 40 g/m² has proven beneficial. In connection with a filament tow filter such as cellulose acetate filter, which can be used alternatively or in addition to a paper filter, the fiber has a denier per filament above 6, preferably at most 8 or less and a total denier below 40,000, preferably equal to 30,000 or less is preferred in order to provide the filter with an acceptably low pressure drop. The filter may possibly contain a breakable capsule containing flavouring agent (e.g., fragrance, aromas dispersed in a lipophilic solvent) for release of flavour on demand such as described in EP1906775.

As will be apparent from above, the article described herein will preferably be used together with an aerosol generating system comprising an aerosol generating device for insertion of the article and heating the aerosol generating substrate. The device will typically comprise a chamber for receiving at least the aerosol generating substrate at a heater configured for heating the substrate in the chamber and for generating aerosol from the substrate passing through the filter when air is drawn through the substrate. The heater can for example be an external tube heater and/or a combination of an induction coil outside the article and susceptors within the article adapted to be heated by the induction coil.

BRIEF DESCRIPTION OF THE DRAWINGS

Hereinafter, the invention will be described with reference to nonlimiting examples and the drawings, in which

FIG. 1 shows a perspective view of a first embodiment of the article,

FIGS. 2-4 show further embodiments, and

FIG. 5 is a diagram illustrating flavour release over time.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

As can be taken from FIG. 1, the article 10 described herein is typically circle cylindrical and essentially has three sections, which can have approximately the same length each: A foam or mousse section 12, which can also be called a plug, a paper tube 14 constituting a spacing and/or cooling element and a filter 16 located at the mouth end of the article, through which vapor including flavour is released to the user. The sections are essentially attached by a paper wrapper, including in particular a tipping paper. A ventilation zone (not shown) may be provided such as by at least one row of ventilation holes through the wrapper, filter and/or paper tube. In the embodiment shown, the plug 12 is surrounded by a heating element 18, which can for example be a heater tube. As per its formulation, the foam has open cell structure (i.e., cells communicating with each other to form a porous 3D network). As indicated by the arrow A, when heated air flows through the article by applying underpressure at the mouth end, the heat flow will extract flavour volatiles and nicotine from the plug and deliver it to the user.

This is enhanced by the through hole 20, which can essentially be at the center of the plug 12 as shown in FIG. 2 and can have diameter approximately one third of the plug's diameter. The extraction of flavour and nicotine is further enhanced by plural through holes as indicated in FIG. 3. These will typically have a smaller diameter than the through hole of the embodiment of FIG. 2. As a result of the surface of the through hole with the foam, the heat flow is increased, and more flavour and nicotine can be extracted. Moreover, plural through holes can be present throughout the plug in addition to those indicated in FIG. 3. As a result of the higher surface of contact of the multiple through holes with the foam, the heat flow capable of transporting volatiles is further increased. Moreover, these through holes as well as the center hole 20 shown in FIG. 2 do not necessarily have to extend fully aligned with the axial or longitudinal direction of the plug typically having a cylindrical shape. Rather, the through holes can extend at an angle to the longitudinal direction and can comprise one or more curves or bends along their extension.

In the embodiment of FIG. 4, the foam or mousse is fragmented into small elements which can have the same or different shapes and sizes. The small elements may be formed as beads, e.g., of a size of one or two millimetres. In any case, plural voids will be present between the elements and enable the heat flow to pass through and extract flavour and nicotine.

Either of the above-described embodiments leads to the flavour and nicotine release shown in FIG. 5, in which flavour and nicotine is released relatively intensively within a short amount of time and is still at a high and relatively constant level after reaching a certain peak. This corresponds well to the experience of regular cigarette smoking, so that users will consider it beneficial and pleasant.

EXAMPLES

Several recipes for the e-mousse were produced in particular:
	Ratio (wt. %)
	Example 1	Example 2	Example 3
E-liquid	68.2	63.4	63.4
Purified water	9.1	9.1	9.1
Gellan gum (Ceroga	4.5	4.5	4.5
Roeper 70f)
Cas no. 71010-52-1
Cellulose fiber (Alba	—	12.0	12.0
fiber or MCC)		Alba fiber	MCC
Carboxymethylcellulose	18.2	11.0	11.0
sodium binder
(Ceroga Roeper 4550C)
Cas no. 9004-32-4

The e-mousse can be flavoured using different flavouring agents in various amounts. The specific e-liquid was PG/VG in a 1:1 ratio and contained flavouring agents and/or nicotine. The amount of flavouring agent can be between 0.5% and 14 wt. %, preferably 3 wt. % and 14 wt. % relative to the weight of the e-mousse. The e-mousse may also contain nicotine in an amount between 0.45 wt. % and 3.4 wt. %, most preferably 1.14 wt. %.

Small cylinders of e-mousse of 7 mm in diameter and 10 mm in length were placed in an oven at a temperature of 200° C. for 60 seconds. A visual observation of the bodies after cooling to ambient temperature show some browning but no significant change of shape and no variation of volume higher than 10%. In example 1, the high amount of binder prevents the material from melting. In examples 2 and 3, the amount of binder and cellulose also prevent the material from melting.

Claims

1. An aerosol generating article (10) for a non-combustion heating aerosol generating device comprising an aerosol generating substrate, anda mouthpiece downstream of the aerosol generating substrate,wherein the aerosol generating substrate is contained in a wrapper and in the form of a foam comprising an aerosol forming agent,a source of nicotine, anda non-tobacco flavouring agent,wherein the mouthpiece comprises a filter and a spacing and/or cooling element is provided between the aerosol generating substrate and the filter, and wherein the aerosol generating substrate comprises between 0.1 and 10 wt. % nicotine in dry basis of the aerosol generating substrate.

2. The aerosol generating article according to claim 1, wherein the aerosol generating substrate is free of tobacco material.

3. The aerosol generating article according to claim 1, wherein the aerosol generating substrate further comprises a foam forming agent and/or a foam stabilizing agent.

4. The aerosol generating article according to claim 1, wherein the aerosol generating substrate comprises between 0.1 and 4 wt. % nicotine in dry basis of the aerosol generating substrate.

5. The aerosol generating article according to claim 1, wherein the aerosol forming agent is present in an amount of at least 30 wt. % of the aerosol generating substrate.

6. The aerosol generating article according to claim 1, wherein the aerosol forming agent is present in an amount comprised between 60 wt. % and 70 wt. % of the aerosol generating substrate.

7. The aerosol generating article according to claim 6, wherein the aerosol forming agent is at least one of glycerol, glycol derivatives, sebacate esters, or mixtures thereof.

8. The aerosol generating article according to claim 6, wherein the aerosol forming agent is a combination of glycerol and propylene glycol.

9. The aerosol generating article according to claim 3, wherein the foam forming agent is at least one of agar, gellan gum, acacia gum, lecithin, polyglycerol esters of fatty acids, glycerol esters of fatty acids, sorbitan esters of fatty acids, or mixtures thereof.

10. The aerosol generating article according to claim 3, wherein the foam stabilizing agent is at least one of cellulose gum, hydroxyalkylated carbohydrates, derivatives thereof, or mixture thereof.

11. The aerosol generating article according to claim 10, wherein the foam stabilizing agent comprises cellulose gum and/or cellulose fibre.

12. The aerosol generating article according to claim 11, wherein the foam stabilizing agent comprises a ratio of between 1:0 and 1:2 of cellulose gum to cellulose fibre in the foam.

13. The aerosol generating article according to claim 12, wherein the cellulose fibre is present in an amount between 5 wt. % and 15 wt. % of the foam.

14. The aerosol generating article according to claim 1, wherein the non-tobacco flavouring agent is at least one of menthol, natural and/or artificial plant or nut flavour, animal flavour, sweet-like, alcoholic or dessert-like flavour, or combinations thereof.

15. The aerosol generating article according to claim 14, wherein the amount of flavouring agent is present in an amount of 0.2 to 18 wt. % of the foam.

16. The aerosol generating article according to claim 1, wherein the aerosol generating substrate extends from an upstream end towards a downstream end of the article.

17. The aerosol generating article according to claim 1, wherein the aerosol generating substrate is in the form of: a hollow tube comprising at least one outlet for air to communicate from outside to an inside of the hollow tube, ora cylindrical rod, ora cylindrical rod comprising a plurality of longitudinal through-passages or channels, ora group of discrete pieces.

18. The aerosol generating article according to claim 1, wherein the spacing and/or cooling element is a hollow paper tube.

19. The aerosol generating article according to claim 18, wherein the hollow paper tube has a length between 10 mm and 25 mm.

20. The aerosol generating article according to claim 1, wherein the filter has a pressure drop lower than 15 mmH2O/mm, wherein the pressure drop is determined under standard conditions defined by Coresta Recommended Method No. 41 (2007) and Coresta Guide No. 4 (2019).

21. The aerosol generating article according to claim 1, wherein the filter comprises a filtering material comprising a paper of basis weight 20 to 40 g/m2.

22. The aerosol generating article according to claim 20, wherein the filter comprises a filtering material comprising a cellulose acetate tow having a denier per filament above 6 and a total denier below 40,000.