Patent Application
20250057205
The present disclosure relates to aerosol-generating compositions and to articles for use in non-combustible aerosol provision devices comprising the aerosol-generating compositions.
Delivery systems include articles for use in non-combustible aerosol provision devices, which comprise material that generates an aerosol when heated. The aerosol may comprise a substance to be delivered. Inhalation of the aerosol by a user facilities delivery of the substance to be delivered to the user.
According to a first aspect of the disclosure, there is provided an aerosol-generating composition comprising a plurality of elongate strips of a first aerosol-generating material, wherein each elongate strip of the first aerosol-generating material comprises corrugations and a longitudinal dimension and wherein the corrugations extend transverse to the longitudinal dimension.
In some embodiments, each elongate strip of the first aerosol-generating material comprises a dimension perpendicular to the longitudinal dimension, wherein the perpendicular dimension is from about 0.5 mm to about 2 mm.
In some embodiments, each elongate strip of the first aerosol-generating material comprises a first surface and a second surface and the first surface and/or the second surface comprises the corrugations.
In some embodiments, each elongate strip has a tensile strength of greater than about 4 N/15 mm.
In some embodiments, the first aerosol-generating material comprises a moisture content of from about 6 wt % to about 12 wt % (OV).
In some embodiments, the first aerosol-generating material comprises an aerosol former in an amount of at least about 10%.
In some embodiments, the first aerosol-generating material comprises botanical material.
In some embodiments, the first aerosol-generating material comprises a binder.
In some embodiments, the first aerosol-generating material comprises or consists of bandcast tobacco.
In some embodiments, the aerosol-generating composition comprises a second aerosol-generating material.
In some embodiments, the second aerosol-generating material comprises a binder, an aerosol former, optionally a flavour, optionally an active and optionally a flavour.
In some embodiments, the second aerosol-generating material comprises a plurality of elongate strips comprising corrugations, wherein each elongate strip of the second aerosol-generating material comprises a longitudinal dimension and wherein the corrugations extend transverse to the longitudinal dimension.
According to a second aspect of the disclosure, there is provided an article for use in a non-combustible aerosol provision device, the article comprising an aerosol-generating composition of the first aspect.
In some embodiments, the article comprising an aerosol-generating composition as described above.
In some embodiments, the first aerosol-generating material comprises a bulk density of from about 500 mg/cm3 to about 1000 mg/cm3.
In some embodiments, the article comprises an aerosol-generating section comprising a rod comprising the aerosol-generating composition circumscribed by a wrapper
In some embodiments, the aerosol-generating composition consists essentially of the first aerosol-generating material.
In some embodiments, the rod comprises a hardness of at least about 80% as measured using Test Method A.
In some embodiments, the aerosol-generating composition has a density of 0.4 to 1 mg/mm3 and a hardness of 80 to 85% as measured using Test Method A.
In some embodiments, the article comprises a proximal end, a distal end and a longitudinal axis extending between the proximal end and the distal end and wherein the corrugations of the elongate strips of the first aerosol-generating material extend transverse relative to the longitudinal axis of the article.
In some embodiments, the article is configured to receive an aerosol generator configured to be inserted into the article such that when the aerosol generator is inserted into, and received by, the article, the aerosol-generator is in contact with the aerosol generating composition.
In some embodiments, the aerosol-generating section is elongate and comprises a pressure drop of from about 1.5 mmWG/mm to about 5 mmWg/mm of a length of the aerosol-generating section.
In some embodiments, the article comprises the aerosol-generating composition in an amount of between about 18 mg/mm of the length of the aerosol-generating section and about 24 mg/mm of the length of the aerosol-generating section.
In some embodiments, the article comprises a hardness of at least about 80%, as measured using Test Method A.
According to a third aspect of the disclosure, there is provided a process for manufacturing an aerosol-generating material, the process comprising:
According to a fourth aspect of the disclosure, there is provided a process for manufacturing an aerosol-generating material, the process comprising:
According to a fifth aspect of the disclosure, there is provided a process for manufacturing an aerosol-generating material, the process comprising:
In some embodiments, the sheet of aerosol-generating material comprises a first surface and a second surface opposite the first surface and the corrugations are formed in the first surface and/or the second surface.
In some embodiments, the elongate strips of aerosol-generating material each comprise a first surface and a second surface opposite the first surface and the corrugations are formed in the first surface and/or the second surface.
In some embodiments, the corrugations are formed by embossing the sheet of aerosol-generating material.
In some embodiments, the process comprises conditioning the sheet of aerosol-generating material at 22° C. at 45% humidity.
In some embodiments, the sheet of aerosol-generating material has a minimum tensile strength of 4 N per 15 mm.
In some embodiments, the aerosol-generating material is the first aerosol-generating material of a composition as described above.
An aerosol-generating material may be prepared using any one of these processes.
According to a sixth aspect of the disclosure, there is provided a device for manufacturing an aerosol-generating material for use in an aerosol-generating composition of the first aspect.
In some embodiments, the device comprises:
In some embodiments, the first rotatable roller and the second rotatable roller are configured to shred a sheet of aerosol-generating material into elongate strips of aerosol-generating material.
In some embodiments, the ridges and groves are configured to emboss corrugations on a sheet of aerosol-generating material as the sheet of aerosol-generating material is moved between the first rotatable roller and the second rotatable roller.
According to a seventh aspect of the disclosure, there is provided a system comprising: an article of the second aspect; and a non-combustible aerosol provision device.
According to an eighth aspect of the disclosure, there is provided a use of an article of the second aspect with a non-combustible aerosol provision device.
b are cross-sectional views of an article for use in a non-combustible aerosol provision device;
As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes:
According to the present disclosure, a “combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user.
In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar.
In some embodiments, the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.
According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.
In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.
In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.
In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine.
In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.
Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.
In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.
In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.
In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.
In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise an aerosol-generating composition comprising aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating section, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.
A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.
According to an aspect of the disclosure, there is provided an aerosol-generating composition. The aerosol-generating composition comprises aerosol-generating material.
An aerosol-generating composition comprises aerosol-generating material, which is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants.
The aerosol-generating material may comprise a binder and an aerosol former. Optionally, an active and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. The aerosol-generating material may comprise botanical material. In some embodiments, the aerosol-generating material is substantially free from botanical material. For example, the aerosol-generating material may be substantially tobacco free.
The aerosol-generating material may comprise or be an “amorphous solid”. The amorphous solid may be a “monolithic solid”. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may, for example, comprise from about 50 wt %, 60 wt % or 70 wt % of amorphous solid, to about 90 wt %, 95 wt % or 100 wt % of amorphous solid.
The aerosol-generating material may comprise or be an aerosol-generating film. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as active substances, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film. The slurry may be heated to remove at least about 60 wt %, 70 wt %, 80 wt %, 85 wt % or 90 wt % of the solvent. The aerosol-generating film may be a continuous film or a discontinuous film, such an arrangement of discrete portions of film on a support. The aerosol-generating film may be substantially tobacco free.
The aerosol-generating material may comprise or be a sheet, which may be shredded to form a shredded sheet.
The aerosol-generating material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.
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.
The active substance may comprise nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.
The active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.
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, 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 Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens
The active substance may comprise, or be derived from, one or more botanicals or constituents, derivatives or extracts thereof, wherein at least one of the botanicals is tobacco.
The active substance may comprise, or be derived from, one or more botanicals or constituents, derivatives or extracts thereof, wherein the botanical is selected from eucalyptus, star anise, cocoa and hemp.
In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof, wherein the botanical is selected from rooibos and fennel.
As used herein, the terms “flavour” and “flavourant” 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 flavour 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), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.
In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.
In some embodiments, the flavour 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 eucolyptol, WS-3.
The aerosol-generating material may comprise a sheet of reconstituted botanical material. The reconstituted botanical material may comprise reconstituted tobacco material. The reconstituted botanical material may comprise at least one of fibres, binder and aerosol former. The reconstituted botanical material may be formed by any suitable process, such as bandcasting process or a papermaking process. The reconstituted botanical material may comprise a sheet comprising cast botanical material (e.g. cast tobacco material). Cast botanical material is a form of reconstituted botanical material that is formed from a slurry including botanical particles, fibre particles, aerosol former and binder. The slurry is then dried to form a sheet of cast botanical material.
The aerosol-generating compositions described herein comprises one or more aerosol-generating materials including, but not limited to, any combination of the aerosol-generating materials described herein. The aerosol-generating composition comprises an aerosol-generating material that is in the form of elongate strips of aerosol-generating material. Any of the aerosol-generating materials described herein can be in the form of the elongate strips. Each elongate strip of aerosol-generating material is generally solid and may be rigid or relatively flexible.
The elongate strips of aerosol-generating material may comprise: a binder, an aerosol former and a filler; a binder, an aerosol former, and a flavour; a binder, an aerosol former, a flavour and a filler; a binder, an aerosol former, and an active; a binder, an aerosol former, an active and a filler; or a binder, an aerosol former, a filler, a flavour and an active.
The elongate strips of aerosol-generating material comprise a longitudinal dimension.
A proportion of the elongate strips comprise corrugations. These corrugations extend transverse to the longitudinal dimension. In other words, the corrugations extend laterally with respect to the longitudinal dimension, across the width of the elongate strips of aerosol-generating material.
The corrugations improve the fill value of the material compared with, for example, elongate strips of aerosol-generating material that do not comprise corrugations. The aerosol-generating material may be incorporated into a variety of aerosol provision systems. For example, the aerosol-generating composition may be wrapped by a wrapper to form a rod of the aerosol-generating composition circumscribed by the wrapper.
The “fill value” (also known as “filling value”) is a measure of the ability of a material to occupy a specific volume at a given moisture content. A high fill value indicates that a lower weight of material is required to produce a rod at acceptable hardness/firmness levels of a given circumference, volume and length than is required with a material of lower fill value.
The aerosol-generating composition may have a fill value of from about 2 cm3/g to about 9 cm3/g.
The elongate strips of aerosol-generating material can have a density of 500 to 1000 mg/cm3.
The corrugations of the elongate strips of aerosol-generating material may help to improve the structural integrity of the aerosol-generating composition, particularly when the composition is incorporated into a consumable. The corrugations of the corrugated elongate strips of aerosol-generating material may interlock with each other, thus helping to prevent relative movement and ensure alignment of the elongate strips of aerosol-generating material when incorporated into an aerosol-generating system.
The elongate strips of aerosol-generating material may have a tensile strength of at least 4 N/15 mm.
In the figures described herein, like reference numerals are used to illustrate equivalent features, articles or components.
Referring to
Referring to
In addition to the elongate strips of the first aerosol-generating material, the aerosol-generating composition may additionally comprise other aerosol-generating materials that are different to the elongate strips of the first aerosol-generating material. These additional aerosol-generating materials may be referred to as second, third, fourth etc. aerosol-generating materials. The additional aerosol-generating materials may also be in the form of elongate strips of aerosol-generating material and they may also be corrugated. For example, the aerosol-generating composition may comprise a population of the elongate strips of the first aerosol-generating material and a population of elongate strips of a second aerosol-generating material that is different to the first aerosol-generating material. The aerosol-generating composition may comprise elongate strips of reconstituted tobacco material and elongate strips of a second aerosol-generating material comprising: a binder; an aerosol former; optionally a flavour; optionally an active; optionally a filler; and optionally a flavour.
The second aerosol-generating material may comprise: a binder, an aerosol former and a filler; a binder, an aerosol former, and a flavour; a binder, an aerosol former, a flavour and a filler; a binder, an aerosol former, and an active; a binder, an aerosol former, an active and a filler; or a binder, an aerosol former, a filler, a flavour and an active.
Including multiple different aerosol-generating materials in the aerosol-generating composition may help to improve the sensory aspects of the aerosol that is generated when the aerosol-generating composition is heated.
Where the aerosol-generating composition comprises multiple different aerosol-generating materials, the second, third, fourth etc. aerosol-generating materials may be in the form of elongate strips comprising corrugations. Similar to the first aerosol-generating material, such elongate strips comprise a longitudinal dimension and the corrugations may extend transverse to the longitudinal dimension
Not all of the different aerosol-generating materials of the aerosol-generating composition need be in the form of strips comprising corrugations. For example, the aerosol-generating composition may comprise of a plurality of elongate, corrugated strips of a first aerosol-generating material and a second aerosol-generating material that does not comprise corrugations. The second aerosol-generating material may be in any suitable form. For example, it may be particulate, granular or it may be in the form of a shredded sheet.
Figure ic shows a composition 101a comprising a first aerosol-generating material 102 and a second aerosol-generating material 109. The corrugations 102a, 102b of adjacent elongate strips 102 of aerosol-generating material 102 are offset with respect to each other. Advantageously, this may help to create voids between adjacent elongate strips of the first aerosol-generating material. As shown in
The second aerosol-generating material may be held firmly between surfaces of adjacent strips of aerosol-generating material. The corrugations may, therefore, help to ensure that the second aerosol-generating material is evenly distributed throughout the aerosol-generating composition.
The fill value of the first aerosol-generating material may be higher than the fill value of the second aerosol-generating material.
Referring now to
As shown in
Referring again to
Alternatively, as shown in
Referring now to
The elongate strips of aerosol-generating material may be relatively flexible and this may allow for the corrugations to move relative to each other (e.g. closer to or further apart from each other). This relative movement of the corrugations allows the elongate strips to be relatively compliant and resiliently deformable.
For example, as shown in
Referring to
Increasing the spacing of the peaks and troughs by increasing the length L1 may increase the filling value of the elongate strips of aerosol-generating material. However, if the distance is too large, then it may be difficult to insert an aerosol generator into the composition comprising the elongate strips of aerosol-generating material. It has been found that a suitable distance between a peak and a trough of the corrugations 102a, 102b may be from about 0.5 mm to about 3 mm, for example, from about 1 mm to about 2 mm.
The corrugations of the elongate strips of aerosol-generating material extend transverse to the longitudinal dimension of the elongate strips. In the embodiments described so far, the corrugations extend transverse and perpendicular to the longitudinal dimension of the elongate strip of aerosol-generating material. However, in other embodiments, the corrugations do not necessarily need to be perpendicular to the longitudinal dimension of the elongate strip of aerosol-generating material.
For example, as shown in
The elongate strips of aerosol-generating material may have any suitable thickness, also referred to herein as depth. Relatively thick elongate strips of aerosol-generating material may be more difficult to manufacture. However, if the elongate strips of aerosol-generating material are too thin, then they may tear easily during the manufacture process and post-manufacturing.
The thickness of the strips may be from about 50 microns to about 400 microns. For example, the thickness of the strips can be about 200 microns, 250 microns or 300 microns. Where the elongate strips of aerosol-generating material are made from bandcast tobacco material, the thickness can be around 250 microns.
The corrugations may be formed on one or more surfaces of the elongate strips. The corrugations may be formed on a single surface of the elongate strips. For example, referring to
The width of the elongate strips of aerosol-generating material may be from about 0.5 mm to about 2 mm. Typically, the elongate strips of aerosol-generating material are about 1 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm or 1.5 mm.
The plurality of elongate strips of the first aerosol-generating may be formed from a sheet of aerosol-generating material. Corrugations may be formed in the sheet of aerosol-generating material to form a corrugated sheet of aerosol-generating material, which is then shredded to from the plurality of elongate strips of aerosol-generating material. The corrugations may be formed by embossing the sheet of aerosol-generating material with a die.
The physical properties of the sheet of aerosol-generating material have a bearing on the quality of the elongate, corrugated strips of aerosol-generating material. If the overall moisture content (OV) of the sheet of aerosol-generating material is too low, then the sheet may not be supple enough to withstand the processing conditions. For example, it may crumble or disintegrate during processing. In order to assist with processing, the sheet of aerosol-generating material may be conditioned prior to the formation of the plurality of elongate strips of aerosol-generating material.
It has been found that processing the sheet of aerosol-generating material by conditioning it, for example at 22° C. and 45% humidity provides a sheet that can be processed to form the elongate, corrugated strips of aerosol-generating material.
Controlling the water content of the sheet of aerosol-generating material helps to ensure that the overall moisture content of the sheet is suitable for processing of the sheet without requiring other components of the sheet of aerosol-generating material, such as the aerosol former, to be altered. The sheet of aerosol-generating material may have a water content of from about 6 wt % to about 13 wt %, from about 6 wt % to about 12 wt %, from about 6 wt % to about 11 wt % or from about 6 wt % to about 10 wt %. It has been observed that a water content below about 6 wt % makes the sheet of aerosol-generating material difficult to process, with small, broken elongate strips of aerosol-generating material being produced. A water content of from about 10 to about 12%, for example around 10.5%, has been found to be particularly beneficial for the formation of the elongate strips of aerosol-generating material. The water content of the aerosol-generating material is measured by Karl Fischer titration.
Referring to
It has been found that the tension of the sheet of aerosol-generating material as it is fed between rollers 602a, 602b affects the properties of the elongate strips of aerosol-generating material. In particular, the depth of the corrugations of the elongate strips of aerosol-generating material (L1) may be influenced by the tension of the sheet of aerosol-generating material. Also, if the tension is not optimal, the elongate strips of aerosol-generating material may break.
It may be necessary to tension the sheet of aerosol-generating material 601 as it is fed between rollers 602a, 602b. For example, as shown in
Referring to
As described previously, the plurality of elongate strips of aerosol-generating material may be formed from a sheet in a single step using apparatus that is configured to both corrugate and cut the sheet of aerosol-generating material. As shown in
The aerosol-generating composition described herein may be incorporated into an article for use in an aerosol provision system. The aerosol provision system may be a non-combustible aerosol provision system, for which the article is suitable for use with.
Referring to
The aerosol-generating composition comprises a plurality of elongate, corrugated strips of a first aerosol-generating material, as described herein.
The longitudinal dimension of each strip of aerosol generating material is in parallel alignment with the longitudinal axis X-X′ of the consumable. The corrugations of each elongate strip of aerosol-generating material extend transverse to the longitudinal axis
X-X′ of the consumable 700.
Orienting the corrugations in this way improves the hardness of the aerosol-generating section of the consumable. The hardness of the aerosol-generating section 702a may be from about 80% to about 90%, or from about 84% to about 87% when measured using
Test Method A, as described herein. Surprisingly, it has been found that the hardness of the aerosol-generating section of the consumable remains relatively consistent even where the mass of aerosol-generating composition is reduced. Without wishing to be bound by theory, it is thought that the corrugations of the elongate strips of aerosol-generating material allow the elongate strips of aerosol-generating material to expand and effectively increase the volume occupied by the aerosol-generating composition. Reducing the mass of the aerosol-generating material in the aerosol-generating section creates free space, which can be filled by the expansion of the corrugated strips of aerosol-generating material. Therefore, the hardness of the aerosol-generating section can be maintained.
In the present example, the aerosol-generating composition is circumscribed by a wrapper 703. The wrapper 703 can be a moisture impermeable wrapper.
In the present example, the rod of the aerosol-generating composition 702 has an outer circumference of about 22.7 mm. In alternative embodiments, the rod of the aerosol-generating composition 702 may have any suitable circumference, for example between about 16 mm and about 26 mm.
The rod of aerosol-generating material has an internal diameter. In the present example, the internal diameter of the rod of the aerosol-generating composition is about 7.2 mm. The rod of aerosol-generating material has a length and in the present embodiment this is about 12 mm.
The article 700 is configured for use in a non-combustible aerosol provision device comprising an aerosol generator for insertion into the aerosol-generating section. In the present example, the aerosol generator is a heater, and the article is configured to receive the aerosol generator in the rod of the aerosol-generating composition.
The wrapper 703 which circumscribes the aerosol-generating composition 702 may comprise a cellulose based material having a basis weight greater than about 40 grams per square metre (gsm), for example, greater than about 30 gsm, preferably greater than about 40 gsm, more preferably greater than about 50 gsm. Such basis weights provide an improved rigidity to the rod of the aerosol-generating composition. In the present example, the wrapper 703 comprises a paper wrapper.
The improved rigidity provided by wrappers having a basis weight greater than about gsm, greater than about 40 gsm, or greater than about 50 gsm, can make the aerosol-generating composition 702 more resistant to crumpling or other deformation under the forces to which the article is subject, in use, for example when the article is inserted into a device and/or a heat generator is inserted into the article.
Providing a rod of the aerosol-generating composition having increased rigidity can be beneficial where the elongate strips of aerosol-generating material are aligned within the aerosol-generating section such that their longitudinal dimension is in parallel alignment with the longitudinal axis, since longitudinally aligned strips of elongate aerosol-generating material may provide less rigidity to the rod of the aerosol-generating composition than when the elongate strips are not aligned. The improved rigidity of the rod of the aerosol-generating composition allows the article to withstand the increased forces to which the article is subject, in use.
In other embodiments, the wrapper 703 optionally comprises a barrier coating to make the material of the wrapper substantially moisture impermeable. For example, a layer of aluminium foil provided on the wrapper 703 has been found to be particularly effective at enhancing the formation of aerosol within the aerosol-generating composition 702. For example, a layer of aluminium foil having a thickness of between about between 4 μm and 16 μm, for example about 6 μm can be provided on the wrapper. Metallic layers or foils other than aluminium can also be used. The total thickness of the wrapper is preferably between 20 μm and 90 μm, more preferably between 30 μm and 60 μm, which can provide a wrapper having appropriate structural integrity and heat transfer characteristics. The tensile force which can be applied to the wrapper before it breaks can be greater than 3,000 grams force, for instance between 3,000 and 10,000 grams force or between 3,000 and 4,500 grams force.
In the present example, the wrapper 703 is also substantially impermeable to air. In alternative embodiments, the wrapper 703 preferably has a permeability of less than 100 Coresta Units, more preferably less than 60 Coresta Units. It has been found that low permeability wrappers, for instance having a permeability of less than 100 Coresta Units, more preferably less than 60 Coresta Units, result in an improvement in the aerosol formation in the aerosol-generating composition 702. Without wishing to be bound by theory, it is hypothesised that this is due to reduced loss of aerosol compounds through the wrapper 703. The permeability of the wrapper 10 can be measured in accordance with ISO 2965:2009 concerning the determination of air permeability for materials used as cigarette papers, filter plug wrap and filter joining paper.
A tipping paper 704 is wrapped around the full length of the mouthpiece 701 and over part of the rod of the aerosol-generating composition 702 and has an adhesive on its inner surface to connect the mouthpiece 701 and rod 702. In the present example, the tipping paper 704 extends 5 mm over the rod of the aerosol-generating composition 702 but it can alternatively extend between 3 mm and 10 mm over the rod 702, or more preferably between 4 mm and 6 mm, to provide a secure attachment between the mouthpiece 701 and rod 702. The tipping paper can have a basis weight greater than gsm, for instance greater than 25 gsm, or preferably greater than 30 gsm, for example 37 gsm. These ranges of basis weights have been found to result in tipping papers having acceptable tensile strength while being flexible enough to wrap around the article 700 and adhere to itself along a longitudinal lap seam on the paper. In the present example, the outer circumference of the tipping paper 704, once wrapped around the mouthpiece 2, is about 23 mm.
The mouthpiece 701 includes a cooling section 705, also referred to as a cooling element, positioned immediately downstream of and adjacent to the aerosol-generating composition 702. In the present example, the cooling section 705 is in an abutting relationship with the source of aerosol-generating material. The mouthpiece 701 also includes, in the present example, a body of material 706 downstream of the cooling section 705, and a hollow tubular element 707 downstream of the body of material 706, at the mouth end of the article 701.
The cooling section 705 comprises a hollow channel, having an internal diameter of between about 1 mm and about 4 mm, for example between about 2 mm and about 4 mm. In the present example, the hollow channel has an internal diameter of about 3.9 mm. The hollow channel extends along the full length of the cooling section 705. In the present example, the cooling section 705 comprises a single hollow channel. In alternative embodiments, the cooling section can comprise multiple channels, for example, 2, 3 or 4 channels. In the present example, the single hollow channel is substantially cylindrical, although in alternative embodiments, other channel geometries/cross-sections may be used. The hollow channel can provide a space into which aerosol drawn into the cooling section 705 can expand and cool down. In all embodiments, the cooling section is configured to limit the cross-sectional area of the hollow channel/s, to limit tobacco displacement into the cooling section, in use.
The moisture impermeable wrapper 703 can have a lower friction with the aerosol-generating material, which can result in the elongate strips of aerosol-generating material being more easily displaced longitudinally, into the cooling section, when the aerosol generator is inserted into the rod of the aerosol-generating composition. Providing a cooling section 705 directly adjacent to the source of aerosol-generating material, and comprising an inner channel with a diameter in this range, advantageously reduces the longitudinal displacement of the elongate strips of aerosol-generating material when the aerosol generator is inserted into the rod of the aerosol-generating composition. Reducing the displacement of aerosol-generating material, in use, can advantageously result in a more consistent packing density of aerosol-generating material along the length of the rod and/or within a cavity, which can result in more consistent and readily controllable aerosol generation.
When the aerosol generator is inserted into the rod of the aerosol-generating composition 3, elongate strips of aerosol-generating material can be displaced longitudinally, into the cooling section. It has been found that providing a cooling section 8 directly adjacent to the source of aerosol-generating material, and comprising an inner channel with a diameter in this range, advantageously reduces the longitudinal displacement of elongate strips of aerosol-generating material when the aerosol generator is inserted into the rod of the aerosol-generating composition. Reducing the displacement of aerosol-generating material, in use, can advantageously result in a more consistent packing density of aerosol-generating material along the length of the rod and/or within a cavity, which can result in more consistent and improved aerosol generation.
The rod of the aerosol-generating composition 702 and the cooling section 705 each have a cross-sectional area, measured perpendicular to the longitudinal axis of the article 700, indicated by the line X-X′ in
Additionally or alternatively, at least about 4% of the cross sectional area of the cooling section can be occupied by the hollow inner channel, or at least about 6%, or at least about 8%. In some examples, between 4% and 32% of the cross sectional area of the cooling section is occupied by the hollow inner channel.
The cooling section 705 preferably has a wall thickness in a radial direction, which can be measured, for example, using a calliper. The wall thickness of the cooling section 705, for a given outer diameter of cooling section, defines the internal diameter for the cavity surrounded by the walls of the cooling section 705. The cooling section 705 preferably has a wall thickness of at least about 1.5 mm and up to about 2 mm. In the present example, the cooling section 705 has a wall thickness of about 1.5 mm.
Providing a cooling section 705 having a wall thickness within this range improves the retention of the source of aerosol-generating material in the aerosol-generating section, in use, by reducing the longitudinal displacement of the elongate strips of aerosol-generating composition when the aerosol generator is inserted into the article.
The cooling section 705 is formed from filamentary tow. Other constructions can be used, such as a plurality of layers of paper which are parallel wound, with butted seams, to form the tubular element 705; or as spirally wound layers of paper, cardboard tubes, tubes formed using a papier-mâché type process, moulded or extruded plastic tubes or similar. The cooling section 705 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 700 is in use.
The filamentary tow material described herein can comprise cellulose acetate fibre tow. The filamentary tow can also be formed using other materials used to form fibres, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch based materials, cotton, aliphatic polyester materials and polysaccharide polymers or a combination thereof. The filamentary tow may be plasticised with a suitable plasticiser for the tow, such as triacetin where the material is cellulose acetate tow, or the tow may be non-plasticised. The tow can have any suitable specification, such as fibres having a ‘Y’ shaped or other cross section such as ‘X’ shaped, filamentary denier values between 2.5 and 15 denier per filament, for example between 8.0 and 11.0 denier per filament and total denier values of 5,000 to 50,000, for example between 10,000 and 40,000.
The filamentary tow forming the cooling section 705 preferably has a denier per filament of greater than 3. This denier per filament has been found to allow the formation of a tubular element 707 which is not too dense. Preferably, the denier per filament is at least 4, more preferably at least 5. In preferred embodiments, the filamentary tow forming the hollow tubular element 707 has a denier per filament between 4 and 10, more preferably between 4 and 9. In one example, the filamentary tow forming the cooling section 705 has an 8Y40,000 tow formed from cellulose acetate and comprising 18% plasticiser, for instance triacetin.
The wall material of the cooling section 705 can be relatively non-porous, such that at least 90% of the aerosol generated by the aerosol-generating composition 702 passes longitudinally through the one or more hollow channels rather than through the wall material of the cooling section 705. For instance, at least 92% or at least 95% of the aerosol generated by the aerosol-generating composition 702 can pass longitudinally through the one or more hollow channels.
Preferably, the length of the cooling section 705 is less than about 30 mm. More preferably, the length of the cooling section 705 is less than about 25 mm. Still more preferably, the length of the cooling section 705 is less than about 20 mm. In addition, or as an alternative, the length of the cooling section 705 is preferably at least about 10 mm. Preferably, the length of the cooling section 705 is at least about 15 mm. In some preferred embodiments, the length of the cooling section 705 is from about 15 mm to about 20 mm, more preferably from about 16 mm to about 19 mm. In the present example, the length of the cooling section 705 is 19 mm.
The cooling section 705 is located around and defines an air gap within the mouthpiece 701 which acts as a cooling section. The air gap provides a chamber through which heated volatilised components generated by the aerosol-generating composition 702 flow. The cooling section 705 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 700 is in use. The cooling section 705 provides a physical displacement between the aerosol-generating composition 702 and the body of material 706. The physical displacement provided by the cooling section 705 will provide a thermal gradient across the length of the cooling section 705.
Preferably, the mouthpiece 701 comprises a cavity having an internal volume greater than 110 mm3. Providing a cavity of at least this volume has been found to enable the formation of an improved aerosol. More preferably, the mouthpiece 701 comprises a cavity, for instance formed within the cooling section 705, having an internal volume greater than 110 mm3, and still more preferably greater than 130 mm3, allowing further improvement of the aerosol. In some examples, the internal cavity comprises a volume of between about 130 mm3 and about 230 mm3, for instance about 134 mm3 or 227 mm3.
The cooling section 705 can be configured to provide a temperature differential of at least 40 degrees Celsius between a heated volatilised component entering a first, upstream end of the cooling section 705 and a heated volatilised component exiting a second, downstream end of the cooling section 705. The cooling section 705 is preferably configured to provide a temperature differential of at least 60 degrees Celsius, preferably at least 80 degrees Celsius and more preferably at least 100 degrees Celsius between a heated volatilised component entering a first, upstream end of the cooling section 705 and a heated volatilised component exiting a second, downstream end of the cooling section 705. This temperature differential across the length of the cooling section 705 protects the temperature sensitive body of material 706 from the high temperatures of the aerosol-generating composition 702 when it is heated.
The body of material 706 and hollow tubular element 705 each define a substantially cylindrical overall outer shape and share a common longitudinal axis. The body of material 706 is wrapped in a first plug wrap 708. Preferably, the first plug wrap 708 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. Preferably, the first plug wrap 708 has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. Preferably, the first plug wrap 708 is a non-porous plug wrap, for instance having a permeability of less than 100 Coresta units, for instance less than 50 Coresta units. However, in other embodiments, the first plug wrap 708 can be a porous plug wrap, for instance having a permeability of greater than 200 Coresta Units.
Preferably, the length of the body of material 706 is less than about 15 mm. More preferably, the length of the body of material 706 is less than about 12 mm. In addition, or as an alternative, the length of the body of material 706 is at least about 5 mm. Preferably, the length of the body of material 706 is at least about 8 mm. In some preferred embodiments, the length of the body of material 706 is from about 5 mm to about 15 mm, more preferably from about 6 mm to about 12 mm, even more preferably from about 6 mm to about 12 mm, most preferably about 6 mm, 7 mm, 8 mm, 9 mm or 10 mm. In the present example, the length of the body of material 6 is 10 mm.
In the present example, the body of material 706 is formed from filamentary tow. In the present example, the tow used in the body of material 706 has a denier per filament (d.p.f.) of 5 and a total denier of 25,000. In the present example, the tow comprises plasticised cellulose acetate tow. The plasticiser used in the tow comprises about 7% by weight of the tow. In the present example, the plasticiser is triacetin. In other examples, different materials can be used to form the body of material 706. For instance, rather than tow, the body 706 can be formed from paper, for instance in a similar way to paper filters known for use in cigarettes. Alternatively, the body 706 can be formed from tows other than cellulose acetate, for instance polylactic acid (PLA), other materials described herein for filamentary tow or similar materials. The tow is preferably formed from cellulose acetate. The tow, whether formed from cellulose acetate or other materials, preferably has a d.p.f. of at least 5. Preferably, to achieve a sufficiently uniform body of material 706, the tow has a denier per filament of no more than 12 d.p.f., preferably no more than 11 d.p.f. and still more preferably no more than d.p.f.
The total denier of the tow forming the body of material 706 is preferably at most 30,000, more preferably at most 28,000 and still more preferably at most 25,000. These values of total denier provide a tow which takes up a reduced proportion of the cross sectional area of the mouthpiece 701 which results in a lower pressure drop across the mouthpiece 701 than tows having higher total denier values. For appropriate firmness of the body of material 706, the tow preferably has a total denier of at least 8,000 and more preferably at least 10,000. Preferably, the denier per filament is between 5 and 12 while the total denier is between 10,000 and 25,000. Preferably the cross-sectional shape of the filaments of tow are ‘Y’ shaped, although in other embodiments other shapes such as ‘X’ shaped filaments can be used, with the same d.p.f. and total denier values as provided herein.
Irrespective of the material used to form the body 706, the pressure drop across body 706, can, for instance, be between 0.3 and 5 mmWG per mm of length of the body 706, for instance between 0.5 mmWG and 2 mmWG per mm of length of the body 706. The pressure drop can, for instance, be between 0.5 and 1 mmWG/mm of length, between 1 and 1.5 mmWG/mm of length or between 1.5 and 2 mmWG/mm of length. The total pressure drop across body 706 can, for instance, be between 3 mmWG and 8 mWG, or between 4 mmWG and 7 mmWG. The total pressure drop across body 706 can be about 5, 6 or 7 mmWG.
As shown in
The terms ‘upstream’ and ‘downstream’ used herein are relative terms defined in relation to the direction of mainstream aerosol drawn through an article or device in use.
Reference to the ‘distal end’ refers to an upstream end of the device, whereas ‘proximal end’ refers to the downstream end of the device.
At the downstream end 700b, the mouthpiece 701 has a hollow tubular element 707 formed from filamentary tow. This has advantageously been found to significantly reduce the temperature of the outer surface of the mouthpiece 701 at the downstream end 700b of the mouthpiece which comes into contact with a consumer's mouth when the article 700 is in use. In addition, the use of the tubular element 707 has also been found to significantly reduce the temperature of the outer surface of the mouthpiece 701 even upstream of the tubular element 707. Without wishing to be bound by theory, it is hypothesised that this is due to the tubular element 707 channelling aerosol closer to the centre of the mouthpiece 701, and therefore reducing the transfer of heat from the aerosol to the outer surface of the mouthpiece 701.
The “wall thickness” of the hollow tubular element 707 corresponds to the thickness of the wall of the tube 707 in a radial direction. This may be measured, for example, using a calliper. The wall thickness is advantageously greater than 0.9 mm, and more preferably 1.0 mm or greater. Preferably, the wall thickness is substantially constant around the entire wall of the hollow tubular element 707. However, where the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm at any point around the hollow tubular element 707, more preferably 1.0 mm or greater. In the present example, the wall thickness of the hollow tubular element 707 is about 1.15 mm.
Preferably, the length of the hollow tubular element 707 is less than about 20 mm. More preferably, the length of the hollow tubular element 707 is less than about 15 mm. Still more preferably, the length of the hollow tubular element 707 is less than about 10 mm. In addition, or as an alternative, the length of the hollow tubular element 707 is at least about 5 mm. Preferably, the length of the hollow tubular element 707 is at least about 6 mm. In some preferred embodiments, the length of the hollow tubular element 707 is from about 5 mm to about 20 mm, more preferably from about 6 mm to about 10 mm, even more preferably from about 6 mm to about 8 mm, most preferably about 6 mm, 7 mm or about 8 mm. In the present example, the length of the hollow tubular element 707 is 7 mm.
Preferably, the density of the hollow tubular element 707 is at least about 0.25 grams per cubic centimetre (g/cc), more preferably at least about 0.3 g/cc. Preferably, the density of the hollow tubular element 707 is less than about 0.75 grams per cubic centimetre (g/cc), more preferably less than 0.6 g/cc. In some embodiments, the density of the hollow tubular element 707 is between 0.25 and 0.75 g/cc, more preferably between 0.3 and 0.6 g/cc, and more preferably between 0.4 g/cc and 0.6 g/cc or about 0.5 g/cc. These densities have been found to provide a good balance between improved firmness afforded by denser material and the lower heat transfer properties of lower density material. For the purposes of the present invention, the “density” of the hollow tubular element 707 refers to the density of the filamentary tow forming the element with any plasticiser incorporated. The density may be determined by dividing the total weight of the hollow tubular element 707 by the total volume of the hollow tubular element 707, wherein the total volume can be calculated using appropriate measurements of the hollow tubular element 707 taken, for example, using callipers. Where necessary, the appropriate dimensions may be measured using a microscope.
The filamentary tow forming the hollow tubular element 707 preferably has a total denier of less than 45,000, more preferably less than 42,000. This total denier has been found to allow the formation of a tubular element 707 which is not too dense. Preferably, the total denier is at least 20,000, more preferably at least 25,000. In preferred embodiments, the filamentary tow forming the hollow tubular element 707 has a total denier between 25,000 and 45,000, more preferably between 35,000 and 45,000. Preferably the cross-sectional shape of the filaments of tow are ‘Y’ shaped, although in other embodiments other shapes such as ‘X’ shaped filaments can be used.
The filamentary tow forming the hollow tubular element 707 preferably has a denier per filament of greater than 3. This denier per filament has been found to allow the formation of a tubular element 707 which is not too dense. Preferably, the denier per filament is at least 4, more preferably at least 5. In preferred embodiments, the filamentary tow forming the hollow tubular element 4 has a denier per filament between 4 and 10, more preferably between 4 and 9. In one example, the filamentary tow forming the hollow tubular element 4 has an 7.3Y36,000 tow formed from cellulose acetate and comprising 18% plasticiser, for instance triacetin.
The hollow tubular element 707 preferably has an internal diameter of greater than 3.0 mm. Smaller diameters than this can result in increasing the velocity of aerosol passing though the mouthpiece 701 to the consumer's mouth more than is desirable, such that the aerosol becomes too warm, for instance reaching temperatures greater than 40° C. or greater than 45° C. More preferably, the hollow tubular element 707 has an internal diameter of greater than 3.1 mm, and still more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the internal diameter of the hollow tubular element 707 is about 3.9 mm.
The hollow tubular element 707 preferably comprises from 15% to 22% by weight of plasticiser. For cellulose acetate tow, the plasticiser is preferably triacetin, although other plasticisers such as polyethelyne glycol (PEG) can be used. More preferably, the tubular element 707 comprises from 16% to 20% by weight of plasticiser, for instance about 17%, about 18% or about 19% plasticiser.
In the present example, the first hollow tubular element 707, body of material 706 and second hollow tubular element 705 are combined using a second plug wrap 709 which is wrapped around all three sections. Preferably, the second plug wrap 709 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 45 gsm. Preferably, the second plug wrap 709 has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The second plug wrap 709 is preferably a non-porous plug wrap having a permeability of less than 100 Coresta Units, for instance less than 50 Coresta Units. However, in alternative embodiments, the second plug wrap 709 can be a porous plug wrap, for instance having a permeability of greater than 200 Coresta Units.
In the present example, the article 700 has an outer circumference of about 23 mm. In other examples, the article can be provided in any of the formats described herein, for instance having an outer circumference of between 15 mm and 25 mm. Since the article is to be heated to release an aerosol, improved heating efficiency can be achieved using articles having lower outer circumferences within this range, for instance circumferences of less than 23 mm. To achieve improved aerosol via heating, while maintaining a suitable product length, article circumferences of greater than 19 mm have also been found to be particularly effective. Articles having circumferences of between 19 mm and 23 mm, and more preferably between 20 mm and 22 mm, have been found to provide a good balance between providing effective aerosol delivery while allowing for efficient heating.
The article has a ventilation level of about 10% of the aerosol drawn through the article. In alternative embodiments, the article can have a ventilation level of between 1% and 20% of aerosol drawn through the article, for instance between 1% and 12%. Ventilation at these levels helps to increase the consistency of the aerosol inhaled by the user at the mouth end 700b, while assisting the aerosol cooling process. The ventilation is provided directly into the mouthpiece 701 of the article 700. In the present example, the ventilation is provided into the cooling section 705, which has been found to be particularly beneficial in assisting with the aerosol generation process. The ventilation is provided via perforations 710, in the present case formed as a single row of laser perforations, positioned 13 mm from the downstream, mouth-end 700b of the mouthpiece 701. In alternative embodiments, two or more rows of ventilation perforations may be provided. These perforations pass though the tipping paper 704, second plug wrap 709 and cooling section 705. In alternative embodiments, the ventilation can be provided into the mouthpiece at other locations, for instance into the body of material 706 or first tubular element 707. Preferably, the article is configured such that the perforations are provided about 28 mm or less from the upstream end of the article 700, preferably between 20 mm and 28 mm from the upstream end of the article 700. In the present example, the apertures are provided about 25 mm from the upstream end of the article.
In the present embodiment, the moisture impermeable wrapper 703 which circumscribes the rod of the aerosol-generating composition comprises aluminium foil. In other embodiments, the wrapper 703 comprises a paper wrapper, optionally comprising a barrier coating to make the material of the wrapper substantially moisture impermeable. Aluminium foil has been found to be particularly effective at enhancing the formation of aerosol within the aerosol-generating composition 702. In the present example, the aluminium foil has a metal layer having a thickness of about 6 μm. In the present example, the aluminium foil has a paper backing. However, in alternative arrangements, the aluminium foil can be other thicknesses, for instance between 4 μm and 16 μm in thickness. The aluminium foil also need not have a paper backing, but can have a backing formed from other materials, for instance to help provide an appropriate tensile strength to the foil, or it can have no backing material. Metallic layers or foils other than aluminium can also be used. The total thickness of the wrapper is preferably between 20 μm and 60 μm, more preferably between 30 μm and 50 μm, which can provide a wrapper having appropriate structural integrity and heat transfer characteristics. The tensile force which can be applied to the wrapper before it breaks can be greater than 3,000 grams force, for instance between 3,000 and 10,000 grams force or between 3,000 and 4,500 grams force. Where the wrapper comprises paper or a paper backing, i.e. a cellulose based material, the wrapper can have a basis weight greater than about 30 gsm, preferably greater than about 40 gsm, more preferably greater than about 50 gsm. Advantageously, such basis weights provide an improved rigidity to the rod of the aerosol-generating composition. The improved rigidity provided by wrappers having a basis weight greater than 30 about gsm, greater than about 40 gsm, or greater than about 50 gsm, can make the rod of the aerosol-generating composition 702 more resistant to crumpling or other deformation under the forces to which the article is subject, in use, for example when the article is inserted into a device and/or a heat generator is inserted into the article.
Providing a rod of the aerosol-generating composition having increased rigidity can be beneficial where a cooling section 705 is included in the article 700, since where a cooling section 705 has an internal diameter less than about 4 mm, as described herein, the insertion force required to insert the article into a device and/or to insert an aerosol generator into the article can be increased. The improved rigidity of the rod of the aerosol-generating composition allows the article to withstand the increased forces to which the article is subject, in use.
In the present example, the moisture impermeable wrapper 703 is also substantially impermeable to air. In alternative embodiments, the wrapper 703 preferably has a permeability of less than 100 Coresta Units, more preferably less than 60 Coresta Units. It has been found that low permeability wrappers, for instance having a permeability of less than 100 Coresta Units, more preferably less than 60 Coresta Units, result in an improvement in the aerosol formation in the aerosol-generating composition 702. Without wishing to be bound by theory, it is hypothesised that this is due to reduced loss of aerosol compounds through the wrapper 703. The permeability of the wrapper can be measured in accordance with ISO 2965:2009 concerning the determination of air permeability for materials used as cigarette papers, filter plug wrap and filter joining paper.
The aerosol-generating section comprises an aerosol-generating composition, as described herein.
For example, with reference to
This arrangement has been found to be particularly advantageous because when an aerosol generator for insertion into the aerosol-generating section is inserted into the aerosol-generating section, the transverse corrugations plurality of elongate strips of aerosol-generating material grip the aerosol generator. This helps to prevent unintentional relative movement between the article and the aerosol generator during use of the non-combustible aerosol provision system.
In some embodiments, some or all of the elongate strips may generally be arranged such that their longitudinal dimension aligned is transverse to the longitudinal axis of the article. For example, at least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or 95% of the elongate strips may be arranged such that their longitudinal dimension in parallel alignment with the longitudinal axis of the of the article. A majority of the elongate strips of aerosol-generating material may be arranged such that their longitudinal dimension is in parallel alignment with the longitudinal axis of the article.
In some embodiments, about 95% to about 100% of the plurality of strips of aerosol-generating material are arranged such that their longitudinal dimension is in parallel alignment with the longitudinal axis of the article. In some embodiments, substantially all of the strips of aerosol-generating material are arranged in the aerosol-generating section such that their longitudinal dimension is in parallel alignment with the longitudinal axis of the aerosol-generating section of the article.
The longitudinal dimension of the plurality of elongate strips of aerosol-generating material may be substantially the same as a length of the aerosol-generating section. The plurality elongate strips may have a length of at least about 5 mm.
When in use, the aerosol-generating section may exhibit a pressure drop of from about to about 40 mm H2O. In some embodiments, the aerosol-generating section exhibits a pressure drop across the aerosol-generating section of from about 15 to about 30 mm H2O.
The aerosol-generating material may have a packing density of between about 400 mg/cm3 and about 900 mg/cm3 or between about 500 mg/cm3 and 1000 mg/cm3 within the aerosol-generating section. A packing density higher than this may make it difficult to insert the aerosol-generator of the aerosol provision device into the aerosol-generating material and increase the pressure drop. A packing density lower than 400 mg/cm3 may reduce the rigidity of the article. Furthermore, if the packing density is too low, the elongate strips of aerosol-generating material may not effectively grip the aerosol-generator of the aerosol provision.
As noted previously, the aerosol-generating material may comprise a mixture of different aerosol-generating materials. In such embodiments, the elongate strips of aerosol-generating material may have a particular distribution in an aerosol-generating section of the article.
For example,
Alternatively, the first aerosol-generating material can be present in region 702c and the second aerosol-generating material can be present in region 702b. The corrugations of the first aerosol-generating material help retain an aerosol-generator (such as a resistive heater) when it is inserted into the composition. Thus, it is possible to take advantage of this property by including the first aerosol-generating material in region 702c whilst enabling the sensory properties to be controlled by including the other aerosol-generating material in region 702b.
A pressure drop across the aerosol-generating section of an article comprising the corrugated elongate strips of aerosol-generating material may be between about 0.3 and 5 mmWG per mm of length of the aerosol-generating section. The pressure drop can between 0.5 mmWG and 2 mmWG per mm of length of the aerosol-generating section. The pressure drop can, for instance, be between 0.5 and 1 mmWG/mm of length, between 1 and 1.5 mmWG/mm of length or between 1.5 and 2 mmWG/mm of length of the aerosol-generating section.
The total pressure drop across the article 700 can, for instance, be between 60 mmWG and 120 mmWG, or between 70 mmWG and 110 mmWG.
The corrugated elongate strips of aerosol-generating material can increase the pressure drop compared with an article that comprises non-corrugated elongate strips of aerosol-generating material. This means that the mass of the aerosol-generating composition in the rod can reduced whilst retaining a preferred pressure drop.
An article comprising an aerosol-generating section in the form of a rod having a volume of about 487.3 mm3 and comprising 25 mg/mm of the rod of an aerosol-generating composition comprising non-corrugated elongate strips of aerosol-generating material has a pressure drop of 2.1 to 3.5 mmWG/mm. The hardness is around 85%.
It has been found that, for a given volume of an aerosol-generating section, a similar pressure drop across the article can be achieved by replacing some or all of this aerosol-generating material with a lower mass of the corrugated elongate strips of aerosol-generating material described herein. Not only that, the hardness of the aerosol-generating section may be maintained at these lower masses.
For example, in an embodiment, an article comprises an aerosol-generating section in the form of a rod having a volume of about 487.27 mm3 and comprising 23.3 mg/mm of an aerosol-generating composition comprising or consisting of a plurality of elongate strips of a first aerosol-generating material, wherein each elongate strip of the first aerosol-generating material comprises corrugations and a longitudinal dimension and wherein the corrugations extend transverse to the longitudinal dimension. The pressure drop across the article of this embodiment is 2.1 to 3.5 mmWg/mm and the hardness is around 86%.
In another embodiment, the article comprises an aerosol-generating section in the form of a rod having a volume of about 487.27 mm3 and comprising 21.6 mg/mm of an aerosol-generating composition comprising or consisting of a plurality of elongate strips of a first aerosol-generating material, wherein each elongate strip of the first aerosol-generating material comprises corrugations and a longitudinal dimension and wherein the corrugations extend transverse to the longitudinal dimension. The pressure drop across the article of this embodiment is 1.88 to 3.13 mmWg/mm and the hardness is around 85%.
The article may be for use in a non-combustible aerosol provision device comprising an aerosol generator for insertion into the aerosol-generating material/consumable.
An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy. The aerosol generator can be configured for insertion into the aerosol-generating section of an article for use with a non-combustible aerosol provision device.
As shown
The non-combustible aerosol provision device 800 comprises a non-combustible aerosol-provision device having a housing 801 comprising an area 802 for receiving an article. The area is in the form of a cavity, open at the proximal end (or mouth end) for receiving an aerosol-generating article. The distal end of the cavity is spanned by an aerosol-generating assembly comprising an aerosol generator 803. In this embodiment, the aerosol-generator is in the form of a resistively-heated elongate pin.
The aerosol generator 803 is retained by a heater mount (not shown) such that an active heating area of the aerosol generator is located within the cavity. The active heating area of the aerosol generator 803 is positioned within the aerosol-generating section of an aerosol-generating article when the aerosol-generating article is fully received within the cavity.
The aerosol generator 803 is configured for insertion into the aerosol-generating section of an aerosol-generating article. As noted above, the aerosol generator 803 is shaped in the form of a pin terminating in a rounded point. The pin has a length dimension that is greater than its width dimension, which is the same as, or similar to, its thickness dimension.
Referring to
Referring now to
When the aerosol-generator 803 is actuated, aerosol-generating material 102 is warmed and volatile substances are generated or evolved. As a user draws on the mouthpiece 701, air is drawn into the article 700 and the volatile substances condense to form an inhalable aerosol. This aerosol passes through the mouthpiece 701 of the article 700 and into the user's mouth.
The aerosol-generating material may release a range of volatile compounds at different temperatures. By controlling the maximum operation temperature of the device 800, the selective release of undesirable compounds may be controlled by preventing the release of select volatile compounds.
As shown in
It has been found that it is possible to insert the aerosol generator into the aerosol-generating section of the article comprising the corrugated elongate strips of aerosol-generating material. Furthermore, once the aerosol generator is inserted into the aerosol-generating composition, the article is securely retained. It has been found that the corrugations increase the force needed to withdraw an aerosol generator from the aerosol-generating section. This makes the article and device easier to use and also safer because the article may be less likely to become displaced from the aerosol generator during use.
For example, in some embodiments, insertion of the aerosol generator into the aerosol-generating section of the article requires a force of less than about 100 N, less than about 90 N, less than about 80 N, less than about 70 N or less than about 60 N. The amount of force required to remove the article from the device can be greater than the insertion force. The amount of force required to remove the article from the device can be greater than at least about 1.9 N, at least about 2 N, at least about 2.1 N, at least about 2.2. N, at least about 2.3 N, at least about 2.4 N, at least about 2.5 N, at least about 2.6 N, at least about 2.7 N, at least about 2.8 N, at least about 2.9 N or at least about 3 N. In some embodiments, the amount of force required to remove the article from the device can be less than 1 N. For example, the amount of force required to remove the article from the device can be between about 0.1 N and 0.8 N.
A sheet of bandcast reconstituted tobacco material conditioned at 22° C. and 45% humidity was shredded using a shredder equipped with two counter-rotating cutting rollers to form a plurality of elongate strips of aerosol-generating material. Each strip was 1 mm wide.
A sheet of bandcast reconstituted tobacco material conditioned at 22° C. and 45% humidity and having a moisture content of 10.94% (measured by Karl Fischer titration) was shredded using a shredder equipped with two rotating cutting rollers comprising a series of ridges and groves on their surfaces to form a plurality of strips of elongate aerosol-generating material. Each strip was 1 mm wide and comprised corrugations extending transverse to the longitudinal dimension of each strip.
Control Article 2a-Articles Comprising Non-Corrugated Elongate Strips of Aerosol-Generating Material
An article was formed comprising a filter section and a 12 mm long rod-shaped aerosol-generating section comprising 300 mg of Control Material 1 circumscribed by a wrapper. The elongate strips of aerosol-generating material were positioned such they were longitudinally aligned with the longitudinal axis of the article.
Control Article 2b-Articles Comprising Non-Corrugated Elongate Strips of Aerosol-Generating Material
An article was formed comprising a filter section and a 12 mm long rod-shaped aerosol-generating section comprising 280 mg of Control Material 1 circumscribed by a wrapper. The elongate strips of aerosol-generating material were positioned such they were longitudinally aligned with the longitudinal axis of the article.
Control Article 2c-Articles Comprising Non-Corrugated Elongate Strips of Aerosol-Generating Material
An article was formed comprising a filter section and a 12 mm long rod-shaped aerosol-generating section comprising 260 mg of Control Material 1 circumscribed by a wrapper. The elongate strips of aerosol-generating material were positioned such they were longitudinally aligned with the longitudinal axis of the article.
An article was formed comprising a filter section and a 12 mm long rod-shaped aerosol-generating section comprising 300 mg of the material of Example 1 circumscribed by a wrapper. The elongate strips of aerosol-generating material were positioned such they were longitudinally aligned with the longitudinal axis of the article. The corrugations extended transverse to the longitudinal axis of the article.
An article was formed comprising a filter section and a 12 mm long rod-shaped aerosol-generating section comprising 280 mg of the material of Example 1 circumscribed by a wrapper. The elongate strips of aerosol-generating material were positioned such they were longitudinally aligned with the longitudinal axis of the article. The corrugations extended transverse to the longitudinal axis of the article.
An article was formed comprising a filter section and a 12 mm long rod-shaped aerosol-generating section comprising 260 mg of the material of Example 1 circumscribed by a wrapper. The elongate strips of aerosol-generating material were positioned such they were longitudinally aligned with the longitudinal axis of the article. The corrugations extended transverse to the longitudinal axis of the article.
The hardness of the aerosol-generating section of the articles described herein is measured using a Borgwaldt H10 hardness tester using the following parameters:
The hardness measurements were taken at the centre (the midpoint with respect to the longitudinal dimension) of the aerosol-generating section (comprising the aerosol-generating composition circumscribed by the wrapper). The hardness is defined as the ratio between the height ho of an aerosol-generating section and the remaining height h, having a defined load applied. It is stated as a percentage of the ho (and therefore has no physical unit of measure). The calculation is as follows:
Upon use of the Borgwaldt H10 device, the samples are placed in the hopper and testing is performed automatically such that each individual sample is measured for both ho and h1 at a first measurement position under the load bar. The sample is then moved to the next measurement position and the heights will be measured again. The process repeats until all samples provided are measured at all measurement positions.
The hardness the aerosol-generating section of the articles of Control Articles 2a-2c and Example Articles 3a-c was measured using Test Method A.
The results are shown in
The hardness of the articles comprising the corrugated elongate strips of aerosol-generating was maintained even as the overall mas of the aerosol-generating composition was decreased.
Control Article 2a and Example Articles 3a to 3c were subjected to pressure drop tests. The pressure drop was measured across the entire article (i.e. between the proximal and distal ends of the article). The results are shown in
For an equivalent mass of material, the pressure drop was higher for Example Article 3a compared with Control Article 2a. Furthermore, a lower mass of corrugated elongate strips of aerosol-generating material was required compared to non-corrugated elongate strips of aerosol-generating material to achieve a similar pressure drop.
The blade heater of a Philip Morris IQOS Duo device was inserted into the aerosol-generating section of Control Articles 2a to 2C and Example Articles 2b and 2C. The forces required to withdraw each article from the device were then analysed using a calibrated Texture Analyser and Exponent software made by (Stable Micro Systems). The results are shown in
For an equivalent mass of material, the force required to withdraw the heater blade from the aerosol-generating section was higher for Examples 2b and 2C.
The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2117953.6 | Dec 2021 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/GB2022/053166 | 12/9/2021 | WO |
