Patent Application
20240188625
The present disclosure relates to an article for use in a non-combustible aerosol provision system.
Certain tobacco industry products produce an aerosol during use, which is inhaled by a user. For example, tobacco heating devices heat an aerosol generating substrate such as tobacco to form an aerosol by heating, but not burning, the substrate. Such tobacco industry products commonly include mouthpieces through which the aerosol passes to reach the user's mouth.
In accordance with some embodiments described herein, there is provided an article for use in a non-combustible aerosol provision system, the article comprising an aerosol generating material and a downstream portion downstream of the aerosol generating material, wherein the downstream portion comprises a cavity surrounded by a paper tube comprising a wall, and wherein said paper tube has a wall thickness of at least 325 microns.
In accordance with some embodiments described herein, there is provided an article for use in a non-combustible aerosol provision system, the article comprising an aerosol generating material and a downstream portion downstream of the aerosol generating material, wherein the downstream portion comprises a cavity surrounded by a paper tube comprising a wall, and wherein said wall has a permeability of at least 100 Coresta Units.
In accordance with some embodiments described herein, there is provided an article for use in a non-combustible aerosol provision system, the article comprising an aerosol generating material and a downstream portion downstream of the aerosol generating material, wherein the downstream portion comprises a cavity surrounded by a paper tube comprising a wall, and wherein said paper tube has a wall thickness of at least 325 microns and/or the wall has a permeability of at least 100 Coresta Units.
In accordance with some embodiments described herein, there is also provided an article for use in a non-combustible aerosol provision system, the article comprising an aerosol generating material and a downstream portion downstream of the aerosol generating material, wherein the downstream portion comprises a cavity surrounded by a tube comprising a wall, and wherein said tube has an axial length of at least 15 mm and wherein said tube has a wall thickness of at least 325 microns.
In accordance with some embodiments described herein, there is also provided an article for use in a non-combustible aerosol provision system, the article comprising an aerosol generating material and a downstream portion downstream of the aerosol generating material, wherein the downstream portion comprises a cavity surrounded by a tube comprising a wall, and wherein said tube has an axial length of at least 15 mm and wherein the wall has a permeability of at least 100 Coresta Units.
In accordance with some embodiments described herein, there is also provided an article for use in a non-combustible aerosol provision system, the article comprising an aerosol generating material and a downstream portion downstream of the aerosol generating material, wherein the downstream portion comprises a cavity surrounded by a tube comprising a wall, and wherein said tube has an axial length of at least 15 mm and wherein said tube has a wall thickness of at least 325 microns and/or the wall has a permeability of at least 100 Coresta Units.
In some embodiments, the tube is adjacent to the aerosol generating material.
In accordance with some embodiments described herein, there is also provided an article for use in a non-combustible aerosol provision system, the article comprising an aerosol generating material and a downstream portion downstream of the aerosol generating material, wherein the downstream portion comprises a cavity surrounded by a tube comprising a wall, and wherein said tube has an axial length of at least 12 mm and is located adjacent to the aerosol generating material, and wherein said tube has a wall thickness of at least 325 microns.
In accordance with some embodiments described herein, there is also provided an article for use in a non-combustible aerosol provision system, the article comprising an aerosol generating material and a downstream portion downstream of the aerosol generating material, wherein the downstream portion comprises a cavity surrounded by a tube comprising a wall, and wherein said tube has an axial length of at least 12 mm and is located adjacent to the aerosol generating material, and wherein the wall has a permeability of at least 100 Coresta Units.
In accordance with some embodiments described herein, there is also provided an article for use in a non-combustible aerosol provision system, the article comprising an aerosol generating material and a downstream portion downstream of the aerosol generating material, wherein the downstream portion comprises a cavity surrounded by a tube comprising a wall, and wherein said tube has an axial length of at least 12 mm and is located adjacent to the aerosol generating material, and wherein said tube has a wall thickness of at least 325 microns and/or the wall has a permeability of at least 100 Coresta Units.
In some embodiments, the tube has a wall thickness of at least 500 microns and, preferably, a thickness of at least 700 microns.
In some embodiments, the tube has a wall thickness of at less than 2000 microns and, preferably, a thickness of less than 1500 microns.
In some embodiments, the wall of the tube has a permeability of at least 500 Coresta Units.
In some embodiments, the wall of the tube has a permeability of at least 1000 Coresta Units and, preferably, at least 2000 Coresta Units.
In some embodiments, the article comprises a ventilation level of about 25%, about 20%, about 12%, about 10%, about 5%, or about 0%.
In some embodiments, the article has an upstream end and a downstream end, and wherein said ventilation level is provided by one or more apertures, wherein the apertures are provided about 28 mm or less from the upstream end of the article, between 20 mm and 28 mm from the upstream end of the article, or about 25 mm from the upstream end of the article.
In some embodiments, the tube comprises one or more ventilation holes and, preferably, the ventilation holes are formed by laser cuts through the thickness of the tube.
In some embodiments, the article further comprises a capsule containing section.
In some embodiments, said ventilation is provided into the capsule containing section, optionally wherein the ventilation is provided immediately upstream of the capsule.
In some embodiments, the capsule has a diameter of less than 3.25 mm.
In some embodiments, the capsule is positioned between about 28 mm and about 38 mm from a distal end of the aerosol-generating material.
In some embodiments, the tube has an axial length of at least 12 mm and, preferably, at least 15 mm or at least 20 mm.
In some embodiments, the tube has an axial length of less than 35 mm and, preferably, less than 30 mm.
In some embodiments, the cavity has a volume of at least 450 mm3 and, preferably, at least 600 mm3.
In some embodiments, the downstream portion further comprises a component downstream of the tube.
In some embodiments, the component comprises a body of material.
In some embodiments, the body of material comprises fibrous material and, preferably, the fibrous material comprises filamentary tow comprising a weight per mm of length of the body of material which is between about 10% and about 30% of the range between the minimum and maximum weights of a tow capability curve generated for the filamentary tow.
In some embodiments, the article further comprises a wrapper that circumscribes the tube.
In some embodiments, the tube comprises paper.
In some embodiments, the tube comprises a fibrous material.
In some embodiments, the fibrous material comprises fibrous tow.
In some embodiments, the tube is a continuous tube of material.
In some embodiments, the tube has a volume of at least 115 mm3.
In some embodiments, the tube defines an internal cavity with a volume of at least 125 mm3.
In some embodiments, the tube defines an internal cavity with a volume of at most 400 mm3.
In some embodiments, at least a portion of the tube is located 24 mm from an upstream end of the article.
In some embodiments, the tube comprises a channel.
In some embodiments, the channel has an internal diameter of between about 1 mm and about 4 mm.
In some embodiments, a maximum of 32% of the cross-sectional area of the tube comprises the channel.
In some embodiments, the channel has an internal diameter of between about 2.5 mm and about 3.9 mm, or between about 2.7 mm and about 3.5 mm, or between about 2.9 mm and about 3.1 mm.
In some embodiments, the aerosol-generating material comprises an aerosol generating section comprising a plurality of strands and/or strips of aerosol-generating material.
In some embodiments, substantially all of the aerosol generating material is formed from sheet material which is folded and/or slit longitudinally to form the aerosol generating section.
In some embodiments, the aerosol-generating section has a length of greater than about 11 mm.
In some embodiments, the aerosol-generating section has a longitudinal dimension, and wherein the strands or strips of aerosol-generating material are aligned in the longitudinal direction, and optionally wherein the strands or strips of aerosol-generating material extend along substantially the full length of the aerosol-generating section in the longitudinal direction.
In some embodiments, at least one of the strands and or strips of aerosol-generating material has a length of at least about 9 mm, or at least about 10 mm, or at least about 11 mm.
In some embodiments, the aerosol-generating section comprises a packing density of strands and or strips of about 400 mg/cm3 and about 900 mg/cm3.
In some embodiments, the aerosol-generating material comprises a reconstituted tobacco material.
In some embodiments, the tobacco material comprises about 10% to about 25% by weight of glycerol.
In some embodiments, the article further comprises a moisture impermeable wrapper that circumscribes the aerosol-generating material and, preferably, the moisture impermeable wrapper comprises a metallic layer and/or has a basis weight greater than about 40 gsm, or greater than about 45 gsm, or greater than about 50 gsm.
In some embodiments, the article is for use in a non-combustible aerosol provision device comprising an aerosol generator for insertion into the aerosol generating material/consumable.
In some embodiments, the article is configured to receive at least a portion of the aerosol generator.
In some embodiments, the article is configured such that, in use, when the aerosol generator is received by the article, the aerosol generator is in direct contact with at least a portion of the aerosol generating material.
In some embodiments, the article is configured such that, in use, insertion of the aerosol generator into the article increases the packing density of the aerosol generating material.
In some embodiments, the aerosol-generating material is less than 20 mm, less than 15 mm or less than 13 mm in length.
In accordance with some embodiments described herein, there is also provided an article for use in a non-combustible aerosol provision system, the article comprising: an aerosol generating material; a downstream portion downstream of the aerosol generating material; a first wrapper comprising sheet material; and, a component that abuts at least a portion of the first wrapper, wherein the first wrapper comprises a plurality of formations configured such that one or more gaps are provided between the first wrapper and the component. In some embodiments, the aerosol generating material is in the form of a rod.
In some embodiments, the component at least partially circumscribes the first wrapper.
In some embodiments, the component comprises a second wrapper that overlies at least a portion of the first wrapper and, preferably, the one or more gaps are provided between the first and second wrappers.
In some embodiments, the second wrapper is an outer wrap.
In some embodiments, the first wrapper at least partially circumscribes the component.
In some embodiments, the component is a component of a plug and, preferably, the component is a plug wrap that circumscribes a plug of material.
In some embodiments, the sheet material has a basis weight of at least 50 gsm and, preferably, at least 60, 70, 80, 90 or 100 gsm.
In some embodiments, the sheet material of the first wrapper is paper.
In some embodiments, the sheet material of the first wrapper comprises a foil and, preferably, a metallic foil.
In some embodiments, the downstream portion comprises a plug and wherein the first wrapper circumscribes the plug.
In some embodiments, the downstream portion comprises a tube and wherein the first wrapper circumscribes the tube.
In some embodiments, the plurality of formations result in non-uniformity in the curvature of at least a portion of the wrapper.
In some embodiments, the formations are embossed.
In some embodiments, the formations are protuberances.
In some embodiments, the protuberances comprise protrusions and, preferably, the protrusions extend from a major surface of the sheet material.
In some embodiments, the protuberances comprise depressions and, preferably, the depression extend into a major surface of the sheet material.
In some embodiments, the protuberances are discrete and spaced apart from each other.
In some embodiments, the protuberances are arranged in a regular array.
In some embodiments, the formations comprise lines of strength discontinuity.
In some embodiments, the plurality of lines of strength discontinuity comprises lines of weakness.
In some embodiments, the lines of weakness comprise partial cuts into the thickness of the sheet material of the first wrapper and, preferably, the partial cuts are on the side of the sheet material that faces inside.
In some embodiments, the partial cuts have been formed by laser cutting.
In some embodiments, the lines of weakness have been formed by pin embossing.
In some embodiments, the article comprises a coating on the sheet material of the first wrapper providing the formations and, preferably, the coating comprises a varnish.
In some embodiments, the formations define a plurality of facets over the first wrapper.
In some embodiments, the facets are generally planar.
In some embodiments, the formations intersect or merge to define facets having a closed shape.
In some embodiments, a plurality of the facets are of the same shape and/or are disposed in an array.
In some embodiments, the article comprises a curved surface around which the sheet material is provided, wherein the first wrapper has a different curvature from that of the curved surface.
In some embodiments, the one or more gaps are configured to permit the flow of ventilation air. The flow of ventilation air helps to lower the temperature of the exterior of the article.
In some embodiments, the formations are configured to form one or more channels (not shown). The gaps may form the channels. Or the gaps may be provided in addition to the channels (for example, on opposite sides of the wrapper). The or each channel may be configured to permit the flow of ventilation air. The flow of ventilation air helps to lower the temperature of the exterior of the article.
The or each channel may be formed between the first wrapper and a component of the article and, preferably, comprises a groove in the first wrapper. For instance, the channel(s) may be formed between the first and second wrappers 9, 5.
In some embodiments, the or each channel extends towards a mouth end of the article such that ventilation air can enter the channel and flow towards the mouth end. Thus, ventilation flow can enter the channel(s) and flow towards the mouth end of the article. In some embodiments, the or each channel extends to the mouth end of the article. Thus, ventilation flow can enter the channel(s) and flow towards the mouth end of the article to exit at the mouth end.
In some embodiments, the or each channel extends substantially parallel to the central axis of the article.
In some embodiments, the article comprises a ventilation zone that overlies at least a part of the channel(s). For example, the ventilation zone may be provided in the second wrapper 5.
In some embodiments, the ventilation zone may comprise perforations in the outer layer of the wrappers such that the ventilation air can flow through the perforations to enter the gaps, for instance, to enter the channels. Alternatively, or additionally, the ventilation zone may comprise a permeable wrapper or permeable area of wrapper.
In accordance with some embodiments described herein, there is also provided an article for use in a non-combustible aerosol provision system, the article comprising: an aerosol generating material in the form of a rod; a downstream portion downstream of the aerosol generating material; a first wrapper comprising sheet material with a plurality of lines of strength discontinuity resulting in non-uniformity in the curvature of at least a portion of the wrapper; and, a second wrapper that overlies at least a portion of the first wrapper such that a plurality of gaps are provided between the first and second wrappers.
In accordance with some embodiments described therein, there is also provided an article for a non-combustible aerosol provision system, wherein the article comprises an aerosol generating material, a downstream portion downstream of the aerosol generating material, and a wrapper, wherein the wrapper is configured such that if the wrapper is subjected to the temperature differential test procedure for a single wrapper as set out herein then the temperature differential ratio is at least 0.2.
In some embodiments, the wrapper comprises paper.
In some embodiments, the wrapper has a basis weight of at least 20 gsm and, preferably, at least 25, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 150 or 170 gsm.
In some embodiments, the wrapper has a basis weight of at most 180 gsm and, preferably, at most 170, 160, 150, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30 or 25 gsm.
In some embodiments, the wrapper has a thickness of at least 20 microns and preferably, has a thickness of at least 30, 40, 50, 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600 microns.
In some embodiments, the wrapper has a thickness of at most 650 microns and preferably, has a thickness of at most 600, 550, 500, 450, 400, 350, 300, 250, 200, 150, 100, 50, 40 or 30 microns.
In some embodiments, the wrapper is substantially non-porous.
In some embodiments, the wrapper is porous.
In some embodiments, the wrapper has a permeability of at least 100 Coresta Units and, preferably, at least 500, 1000, 2000, 5000, 10000, 12000, 15000, 17000, 20000, 22000 or 25000 Coresta Units.
In some embodiments, the wrapper is configured such that if the wrapper is subjected to the temperature differential test procedure for a single wrapper as set out herein then the temperature differential ratio is at least 0.22 and, preferably, at least 0.25, 0.3, 0.35, 0.4, 0.45, 0.5 or 0.55.
In some embodiments, the wrapper is a plug wrap.
In some embodiments, the wrapper is a tipping wrapper that attaches the downstream portion to the aerosol generating material.
In accordance with some embodiments described therein, there is also provided an article for a non-combustible aerosol provision system, wherein the article comprises an aerosol generating material, a downstream portion downstream of the aerosol generating material, and a plurality of wrappers that form a collation of wrappers, wherein the collation of wrappers is configured such that if the collation of wrappers is subjected to the temperature differential test procedure for a collation of wrappers as set out herein then the temperature differential ratio is at least 0.3.
In some embodiments, collation of wrappers is configured such that if the collation of wrappers is subjected to the temperature differential test procedure for a collation of wrappers as set out herein then the temperature differential ratio is at least 0.32 and, preferably, at least 0.35, 0.4, 0.45, 0.5, 0.55 or 0.6.
In some embodiments, at least one wrapper of the collation of wrappers comprises paper.
In some embodiments, at least one wrapper of the collation of wrappers has a basis weight of at least 20 gsm and, preferably, at least 25, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 150 or 170 gsm. In some embodiments a first, second and/or third wrapper of the collation of wrappers may have such a basis weight.
In some embodiments, at least one wrapper of the collation of wrappers has a basis weight of at most 180 gsm and, preferably, at most 170, 160, 150, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30 or 25 gsm. In some embodiments, a first, second and/or third wrapper of the collation of wrappers may have such a basis weight.
In some embodiments, at least one wrapper of the collation of wrappers has a thickness of at least 20 microns and preferably, has a thickness of at least 30, 40, 50, 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600 microns. In some embodiments, a first, second and/or third wrapper of the collation of wrappers may have such a thickness.
In some embodiments, at least one wrapper of the collation of wrappers has a thickness of at most 650 microns and preferably, has a thickness of at most 600, 550, 500, 450, 400, 350, 300, 250, 200, 150, 100, 50, 40 or 30 microns. In some embodiments, a first, second and/or third wrapper of the collation of wrappers may have such a thickness.
In some embodiments, at least one wrapper of the collation of wrappers is substantially non-porous.
In some embodiments, at least one wrapper of the collation of wrappers is porous.
In some embodiments, at least one wrapper of the collation of wrappers has a permeability of at least 100 Coresta Units and, preferably, at least 500, 1000, 2000, 5000, 10000, 12000, 15000, 17000, 20000, 22000 or 25000 Coresta Units.
In some embodiments, at least one wrapper of the collation of wrappers is configured such that if the wrapper is subjected to the temperature differential test procedure for a single wrapper as set out herein then the temperature differential ratio is at least 0.2 and, preferably, at least 0.22, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5 or 0.55.
In some embodiments, the collation of wrappers comprises a first wrapper.
In some embodiments, the first wrapper circumscribes a component of the article and, preferably, wherein the component is a tube or plug of material of the article.
In some embodiments, the first wrapper contacts the component of the article.
In some embodiments, the collation of wrappers comprises a second wrapper.
In some embodiments, the second wrapper connects the downstream portion to the aerosol generating material.
In some embodiments, the second wrapper is an outermost wrapper of the article.
In some embodiments, the collation of wrappers comprises a third wrapper.
In some embodiments, the third wrapper is configured to connect first and second components of the article.
In some embodiments, the third wrapper is located between the first and second wrappers.
In some embodiments, the aerosol generating material comprises a first aerosol generating material, and the article further comprises a component downstream of the first aerosol generating material, wherein the component comprises a tubular portion and wherein the tubular portion comprises a wall comprising a second aerosol generating material.
In some embodiments, the aerosol generating material is wrapped by a wrapper having a level of permeability greater than about 2000 Coresta Units, and wherein the article comprises a downstream portion downstream of the aerosol generating material, comprising at least one ventilation area.
In some embodiments, the article is configured such that when the article is inserted into a non-combustible aerosol provision device, the minimum distance between a heater of the non-combustible aerosol provision device and a tubular section of the article is at least about 3 mm.
In some embodiments, the level of ventilation provided by said one or more ventilation holes is within the range of 45% to 65% of the volume of aerosol passing through the component, or between 40% and 60% of the volume of aerosol passing through the component.
In some embodiments, the article comprises a hollow tubular element extending from a mouth end of the article, wherein the hollow tubular element comprises a length of greater than about 10 mm or greater than about 12 mm.
In accordance with some embodiments described therein, there is also provided a non-combustible aerosol provision system comprising an article as described herein.
In some embodiments, the article comprises an aerosol modifying component and a heater which, in use, is operable to heat the aerosol generating material such that the aerosol generating material provides an aerosol, wherein the aerosol modifying component is downstream of the aerosol generating material and comprises: a first capsule in a first portion of the aerosol modifying component, wherein the first portion of the aerosol modifying component is heated to a first temperature during operation of the heater to generate the aerosol; and, a second capsule in a second portion of the aerosol modifying component located downstream of the first portion, wherein the second portion is heated to a second temperature during operation of the heater to generate aerosol, and wherein the second temperature is at least 4 degrees Celsius lower than the first temperature.
In some embodiments, the non-combustible aerosol provision system is an aerosol generating material heating system and, preferably is a tobacco heating system.
In accordance with some embodiments described therein, there is also provided a non-combustible aerosol provision system comprising an article as described herein and a non-combustible aerosol provision device, wherein the non-combustible aerosol provision device comprises an aerosol generator configured for insertion into the aerosol generating material/consumable.
Embodiments will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:
According to the present disclosure, a “combustible” aerosol provision system is one where a constituent aerosolisable material of the aerosol provision system (or component thereof) is combusted or burned in order to facilitate delivery to a user.
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 delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.
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 aerosol-generating material, an aerosol-generating material storage area, 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.
In some embodiments, the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolised. As appropriate, either 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.
In some embodiments, the substance to be delivered comprises an active substance.
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.
In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.
As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term “botanical” includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, 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, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens
In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.
In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and 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 and the botanical is selected from rooibos and fennel.
In some embodiments, the substance to be delivered comprises a flavour.
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.
Aerosol-generating material is a material that 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 gel which may or may not contain an active substance and/or flavourants. The aerosol generating material may be incorporated into an article for use in the aerosol-generating system. In some embodiments, the aerosol-generating material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). 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 one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.
The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.
The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.
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.
A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.
An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent
The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.
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.
Articles, for instance those in the shape of rods, are often named according to the product length: “regular” (typically in the range 68-75 mm, e.g. from about 68 mm to about 72 mm), “short” or “mini” (68 mm or less), “king-size” (typically in the range 75-91 mm, e.g. from about 79 mm to about 88 mm), “long” or “super-king” (typically in the range 91-105 mm, e.g. from about 94 mm to about 101 mm) and “ultra-long” (typically in the range from about 110 mm to about 121 mm).
They are also named according to the product circumference: “regular” (about 23-25 mm), “wide” (greater than 25 mm), “slim” (about 22-23 mm), “demi-slim” (about 19-22 mm), “super-slim” (about 16-19 mm), and “micro-slim” (less than about 16 mm).
Accordingly, an article in a king-size, super-slim format will, for example, have a length of about 83 mm and a circumference of about 17 mm.
Each format may be produced with mouthpieces of different lengths. The mouthpiece length will be from about 30 mm to 50 mm. A tipping paper connects the mouthpiece to the aerosol generating material and will usually have a greater length than the mouthpiece, for example from 3 to 10 mm longer, such that the tipping paper covers the mouthpiece and overlaps the aerosol generating material, for instance in the form of a rod of substrate material, to connect the mouthpiece to the rod.
Articles and their aerosol generating materials and mouthpieces described herein can be made in, but are not limited to, any of the above formats.
The terms ‘upstream’ and ‘downstream’ used herein are relative terms defined in relation to the direction of mainstream aerosol drawn though an article or device 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.
As used herein, the term “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/or tobacco extract.
In the figures described herein, like reference numerals are used to illustrate equivalent features, articles or components.
The article 1 comprises a mouthpiece 2, and an aerosol generating material 3, in the present case tobacco material, connected to the mouthpiece 2. The aerosol generating material may be in the form of an aerosol generating section, which in the present example is a cylindrical rod. The aerosol generating material 3 provides an aerosol when heated, for instance within a non-combustible aerosol provision device as described herein, for instance a non-combustible aerosol provision device comprising a coil, forming a system. In other embodiments the article 1 can include its own heat source, forming an aerosol provision system without requiring a separate aerosol provision device.
In the present example, the aerosol generating section comprises a source of aerosol-generating material in the form of a cylindrical rod of aerosol-generating material 3. In other examples, the aerosol-generating section may comprise a cavity for receiving a source of aerosol-generating material. In some embodiments, the aerosol-generating material comprises a plurality of strands or strips of aerosol generating-material. For example, the aerosol-generating material may comprise a plurality of strands or strips of an aerosolisable material and/or a plurality of strands or strips of an amorphous solid, as described hereinbelow. In some embodiments, the aerosol-generating material consists of a plurality of strands or strips of an aerosolisable material.
In one embodiment, the aerosol-generating material 3 comprises a plurality of strands and/or strips of aerosol-generating material, and is circumscribed by a wrapper 10. In the present example, the wrapper 10 is a moisture impermeable wrapper.
The plurality of strands or strips of aerosol-generating material may be aligned within the aerosol-generating section such that their longitudinal dimension is in parallel alignment with the mouthpiece 2 andlongitudinal axis, X-X′ of the article 1. Alternatively, the strands or strips may generally be arranged such that their longitudinal dimension aligned is transverse to the longitudinal axis of the article.
At least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or 95% of the plurality of strands or strips may be arranged such that their longitudinal dimension is in parallel alignment with the longitudinal axis of the article. A majority of the strands or strips may be arranged such that their longitudinal dimensions are in parallel alignment with the longitudinal axis of the article. In some embodiments, about 95% to about 100% of the plurality of strands or strips 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 strands or strips 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 inventors have found that, where the majority of the strands or strips are arranged in the aerosol-generating section such that their longitudinal axis is parallel with the longitudinal axis of the aerosol-generating section of the article, the force required to insert an aerosol generator into the aerosol-generating material can be relatively low. This can result in an article which is easier to use.
In some embodiments, all of the aerosol generating material 3 is formed from sheet material which is folded and/or slit longitudinally to form the aerosol generating section.
In some embodiments, the aerosol-generating section has a length of greater than about 11 mm.
In some embodiments, the aerosol-generating section 3 has a longitudinal dimension, and wherein the strands or strips of aerosol-generating material 3 are aligned in the longitudinal direction, and optionally wherein the strands or strips of aerosol-generating material 3 extend along substantially the full length of the aerosol-generating section in the longitudinal direction.
In some embodiments, at least one of the strands and or strips of aerosol-generating material 3 has a length of at least about 9 mm, or at least about 10 mm, or at least about 11 mm.
In some embodiments, the aerosol-generating section 3 comprises a packing density of strands and or strips of about 400 mg/cm3 and about 900 mg/cm3.
In some embodiments, the aerosol-generating material 3 comprises a reconstituted tobacco material. In some embodiments, the tobacco material comprises about 10% to about 25% by weight of glycerol.
In some embodiments, a moisture impermeable wrapper circumscribes the aerosol-generating material 3. The moisture impermeable wrapper may comprise a metallic layer, for example, aluminium. The moisture impermeable wrapper may have a basis weight greater than about 40 gsm, or greater than about 45 gsm, or greater than about 50 gsm.
In some embodiments, the article 1 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 formed from a heater, and the article is configured to receive the aerosol generator in the rod of aerosol-generating material.
The aerosol generating material 3, also referred to herein as an aerosol generating substrate 3, comprises at least one aerosol-former material. In the present example, the aerosol-former material is glycerol. In alternative examples, the aerosol-former material can be another material as described herein or a combination thereof. The aerosol-former material has been found to improve the sensory performance of the article, by helping to transfer compounds such as flavour compounds from the aerosol generating material to the consumer. However, an issue with adding such aerosol-former materials to the aerosol generating material within an article for use in a non-combustible aerosol provision system can be that, when the aerosol-former material is aerosolised upon heating, it can increase the mass of aerosol which is delivered by the article, and this increased mass can maintain a higher temperature as it passes through the mouthpiece. As it passes through the mouthpiece, the aerosol transfers heat into the mouthpiece and this warms the outer surface of the mouthpiece, including the area which comes into contact with the consumers lips during use. The mouthpiece temperature can be significantly higher than consumers may be accustomed to when smoking, for instance, conventional cigarettes, and this can be an undesirable effect caused by the use of such aerosol-former materials.
In the present example, the mouthpiece includes a tubular portion 4a, in the present example formed by a hollow tube, also referred to as a cooling element or cooling section. The mouthpiece 2, in the present example, includes a body of material 6 downstream of the tubular portion 4a, in this example adjacent to and in an abutting relationship with the tubular portion 4a. The body of material 6 and tubular portion 4a each define a substantially cylindrical overall outer shape and share a common longitudinal axis.
The tubular portion 4a 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 mm. The hollow channel extends along the full length of the tubular portion 4a. In the present example, the tubular portion 4a comprises a single hollow channel. In alternative embodiments, the tubular portion 4a comprises 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 tubular portion 4a can expand and cool down. In all embodiments, the tubular portion 4a is configured to limit the cross-sectional area of the hollow channel/s, to limit tobacco displacement into the cooling section, in use.
The rod of aerosol generating material 3 and the cooling section, which in the present example is a tubular portion 4a, each have a cross-sectional area, measured perpendicular to the longitudinal axis of the article 1. The cooling section is configured so that a maximum percentage of the cross sectional area of the cooling section is occupied by the one or more hollow channels, for example less than about 45% of the cross sectional area, less than about 32% of the cross sectional area, or less than about 25% of the cross sectional area. In the present example, about 18% of the cross sectional area of the cooling section is occupied by the hollow channel. 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. Table 1 provides exemplary percentages of cooling section cross sectional area occupied by a hollow cooling channel of either 3 or 3.9 mm internal diameter, for a range of cooling section diameters. For the purpose of this calculation, the cross sectional area of the cooling section is calculated based on the diameter of the cooling section without tipping paper applied, and the measurement is based on the dimensions of the cooling section which directly abuts the aerosol-generating section.
The body of material 6 is wrapped in a first plug wrap 7. In the present example, the tubular portion 4a and body of material 6 are combined using a second plug wrap 9 which is wrapped around both sections. A tipping paper 5 is wrapped around the full length of the mouthpiece 2 and over part of the rod of aerosol generating material 3 and has an adhesive on its inner surface to connect the mouthpiece 2 and rod 3.
In the present example, the tubular portion 4a is formed from a plurality of layers of paper which are parallel wound, with butted seams, to form a hollow tube. In the present example, first and second paper layers are provided in a two-ply tube, although in other examples 3, 4 or more paper layers can be used forming 3, 4 or more ply tubes. Other constructions can be used, such as spirally wound layers of paper, cardboard tubes, tubes formed using a papier-mâché type process, moulded or extruded plastic tubes or similar.
The tubular portion 4a preferably has a wall 4b thickness of at least about 325 μm and up to about 2 mm, preferably between 500 μm and 1.5 mm and more preferably between 750 μm and 1 mm. In the present example, the tubular portion 4a has a wall thickness of about 1 mm. The “wall thickness” of the tubular portion 4a corresponds to the thickness of the wall of the tubular portion 4a in a radial direction. This may be measured, for example, using a calliper.
In some embodiments, the thickness of the wall 4b of the tubular portion 4a is at least 325 microns and, preferably, at least 400, 500, 600, 700, 800, 900 or 1000 microns. In some embodiments, the thickness of the wall 4b of the tubular portion 4a is at least 1250 or 1500 microns.
In some embodiments, the thickness of the wall 4b of the tubular portion 4a is less than 2500 microns, preferably less than 2000 microns and, preferably, less than 1500 microns.
The increased thickness of the wall 4b of the tubular portion 4a means that it has a greater thermal mass, which has been found to help reduce the temperature of the aerosol passing through the tubular portion 4a and reduce the surface temperature of the mouthpiece 2 at locations downstream of the tubular portion 4a. This is thought to be because the greater thermal mass of the tubular portion 4a allows the tubular portion 4a to absorb more heat from the aerosol in comparison to a tubular portion with a thinner wall thickness. The increased thickness of the tubular portion 4a also channels the aerosol centrally within the mouthpiece 2, 2′ such that less heat from the aerosol is transferred to the outer portions of the mouthpiece 2, 2′ such as outer portions of the body of material 6.
The tubular portion 4a 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 1 is in use.
The wall material of the tubular portion 4a can be relatively non-porous, such that at least 90% of the aerosol generated by the aerosol generating material 3 passes longitudinally through the one or more hollow channels rather than through the wall material of the tubular portion 4a. For instance, at least 92% or at least 95% of the aerosol generated by the aerosol generating material 3 can pass longitudinally through the one or more hollow channels.
In some embodiments, the tubular portion 4a comprises a plurality of layers of paper which are parallel wound, with butted seams, to form the cooling section 8; or as spirally wound layers of paper, cardboard tubes, tubes formed using a papier-mâché type process, moulded or extruded plastic tubes or similar.
In some alternative embodiments, the tubular portion 4a is formed from filamentary tow. The filamentary tow forming the tubular portion 4a 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 portion 4a 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 tubular portion 4a 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 tubular portion 4a preferably has a denier per filament of greater than 3. This denier per filament has been found to allow the formation of a tubular portion 4a 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 portion 4a 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 8 has an 8Y40,000 tow formed from cellulose acetate and comprising 18% plasticiser, for instance triacetin.
Preferably, the density of the material forming the tubular portion 4a is at least about 0.20 grams per cubic centimetre (g/cc), more preferably at least about 0.25 g/cc. Preferably, the density of the material forming the tubular portion 4a is less than about 0.80 grams per cubic centimetre (g/cc), more preferably less than 0.6 g/cc. In some embodiments, the density of the material forming the tubular portion 4a is between 0.20 and 0.8 g/cc, more preferably between 0.3 and 0.6 g/cc, or 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 minimising the overall weight of the article. For the purposes of the present disclosure, the “density” of the material forming the tubular portion 4a refers to the density of any filamentary tow forming the element with any plasticiser incorporated. The density may be determined by dividing the total weight of the material forming the tubular portion 4a by the total volume of the material forming the tubular portion 4a, wherein the total volume can be calculated using appropriate measurements of the material forming the tubular portion 4a taken, for example, using callipers. Where necessary, the appropriate dimensions may be measured using a microscope.
The article 1 has a ventilation level of about 75% of the aerosol drawn through the article. In alternative embodiments, the article can have a ventilation level of between 50% and 80% of aerosol drawn through the article, for instance between 65% and 75%. Ventilation at these levels helps to slow down the flow of aerosol drawn through the mouthpiece 2 and thereby enable the aerosol to cool sufficiently before it reaches a downstream end 2b of the mouthpiece 2. The ventilation is provided directly into the mouthpiece 2 of the article 1. In the present example, the ventilation is provided into the tubular portion 4a, which has been found to be particularly beneficial in assisting with the aerosol generation process. The ventilation is provided via first and second parallel rows of ventilation holes 12, in the present case formed as laser perforations, at positions 17.925 mm and 18.625 mm respectively from the downstream, mouth-end 2b of the mouthpiece 2. These ventilation holes 12 pass though the tipping paper 5, second plug wrap 9 and tubular portion 4a. In alternative embodiments, the ventilation can be provided into the mouthpiece at other locations. For example, the ventilation may be provided into the body of material 6.
Alternatively, the ventilation can be provided via a single row of ventilation holes, for instance laser perforations, into the portion of the article in which the tubular body 4a is located. This has been found to result in improved aerosol formation, which is thought to result from the airflow through the ventilation holes being more uniform than with multiple rows of ventilation holes, for a given ventilation level.
Aerosol temperature has been found to generally increase with a drop in the ventilation level. However the relationship between aerosol temperature and ventilation level does not appear to be linear, with variations in ventilation, for instance due to manufacturing tolerances, having less impact at lower target ventilation levels. For instance, with a ventilation tolerance of +15%, for a target ventilation level of 75%, the aerosol temperature could increase by approximately 6° C. at the lower ventilation limit (60% ventilation). However, with a target ventilation level of 60% the aerosol temperature may only increase by approximately 3.5° C. at the lower vent limit (45% ventilation). The target ventilation level of the article can therefore be within the range 40% to 70%, for instance, 45% to 65%. The mean ventilation level of at least 20 articles can be between 40% and 70%, for instance between 45% and 70% or between 51% and 59%.
In some embodiments, the permeability of the wall 4b of the tubular portion 4a is at least 100 Coresta Units and, preferably, at least 500 Coresta Units. In some embodiments, the permeability is at least 1000 or 2000 Coresta Units. The permeability of the material of the wall 4b of the tubular portion 4a 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.
It has been found that the relatively high permeability of the tubular portion 4a increases the amount of heat that is transferred to the tubular portion 4a from the aerosol and thus reduces the temperature of the aerosol. The permeability of the tubular portion 4a has also been found to increase the amount of moisture that is transferred from the aerosol to the tubular portion 4a, which has been found to improve the feel of the aerosol in the user's mouth. A high permeability of tubular portion 4a also makes it easier to cut the ventilation holes 12 using a laser, meaning that a lower power of laser can be used.
In other embodiments, 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 2b, while assisting the aerosol cooling process. The ventilation is provided directly into the mouthpiece 2 of the article 1. In the present example, the ventilation is provided into the tubular portion 4a, which has been found to be particularly beneficial in assisting with the aerosol generation process. The ventilation is provided via perforations, in the present case formed as a single row of laser perforations, positioned 13 mm from the downstream, mouth-end 2b of the mouthpiece 2. In alternative embodiments, two or more rows of ventilation perforations may be provided. These perforations pass though the tipping paper 5, second plug wrap 9 and tubular portion 4a. In alternative embodiments, the ventilation can be provided into the mouthpiece at other locations, for instance into the body of material 6 or hollow tubular679 element 8. Preferably, the article is configured such that the perforations are provided about 28 mm or less from the upstream end of the article 1, preferably between 20 mm and 28 mm from the upstream end of the article 1. In the present example, the apertures are provided about 25 mm from the upstream end of the article.
In some examples, the aerosol generating material 3 described herein is a first aerosol generating material and the tubular portion 4a may include a second aerosol generating material. In one example, wall 4b of tubular portion 4a comprises the second aerosol generating material. For example, the second aerosol generating material can be disposed on an inner surface of wall 4b of the tubular portion 4a.
The second aerosol generating material comprises at least one aerosol former material, and may also comprise at least one aerosol modifying agent, or other sensate material. The aerosol former material and/or aerosol modifying agent can be any aerosol former material or aerosol modifying agent as described herein, or a combination thereof.
As the aerosol generated from aerosol generating material 3, referred to herein as the first aerosol, is drawn through the tubular portion 4a of the mouthpiece, heat from the first aerosol may aerosolise the aerosol forming material of the second aerosol generating material, to form a second aerosol. The second aerosol may comprise a flavourant, which may be additional or complementary to the flavour of the first aerosol.
Providing a second aerosol generating material on the tubular body 4a can result in generation of a second aerosol which boosts or complements the flavour or visual appearance of the first aerosol.
In the present example, the article 1 has an outer circumference of about 21 mm (i.e. the article is in the demi-slim format). Preferably, the article 1 has a rod of aerosol generating material having a circumference greater than 19 mm. This has been found to provide a sufficient circumference to generate an improved and sustained aerosol over a usual aerosol generation session preferred by consumers. As the article is heated, heat transfers through the rod of aerosol generating material 3 to volatise components of the rod, and circumferences greater than 19 mm have been found to be particularly effective at producing an aerosol in this way. Since the article is to be heated to release an aerosol, improved heating efficiency can be achieved using articles having circumferences of less than about 23 mm. To achieve improved aerosol via heating, while maintaining a suitable product length, rod circumferences of greater than 19 mm and less than 23 mm are preferable. In some examples, the rod circumference can be between 20 mm and 22 mm, which has been found to provide a good balance between providing effective aerosol delivery while allowing for efficient heating. In other examples, the article can be provided in any of the formats described herein, for instance having an outer circumference of between 20 mm and 26 mm.
The outer circumference of the mouthpiece 2 is substantially the same as the outer circumference of the rod of aerosol generating material 3, such that there is a smooth transition between these components. In the present example, the outer circumference of the mouthpiece 2 is about 20.8 mm.
In the present example, the tipping paper 5 extends 5 mm over the rod of aerosol generating material 3 but it can alternatively extend between 3 mm and 10 mm over the rod 3, or more preferably between 4 mm and 6 mm, to provide a secure attachment between the mouthpiece 2 and rod 3. The tipping paper can have a basis weight greater than 20 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 1 and adhere to itself along a longitudinal lap seam on the paper. The outer circumference of the tipping paper 5, once wrapped around the mouthpiece 2, is about 23 mm.
In some embodiments, the tipping paper 5 can have a basis weight which is higher than the basis weight of plug wraps used in the article 1, for instance a basis weight of 40 gsm to 80 gsm, more preferably between 50 gsm and 70 gsm, and in the present example 58 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 1 and adhere to itself along a longitudinal lap seam on the paper. The outer circumference of the tipping paper 5, once wrapped around the mouthpiece 2, is about 21 mm.
In some examples, the tipping paper 5 comprises citrate, such as sodium citrate or potassium citrate. In such examples, the tipping paper 5 may have a citrate content of 2% by weight or less, or 1% by weight or less. Reducing the citrate content of the tipping paper 5 is thought to assist with reducing the charring effect which may occur during use.
In some embodiments, the first plug wrap 7 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. Preferably, the first plug wrap 7 has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. Preferably, the first plug wrap 7 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 7 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 6 is less than about 20 mm. In the present example, the length of the body of material 6 is 16 mm.
Preferably, the length of the body of material 6 is less than about 15 mm. More preferably, the length of the body of material 6 is less than about 12 mm. In addition, or as an alternative, the length of the body of material 6 is at least about 5 mm. Preferably, the length of the body of material 6 is at least about 8 mm. In some preferred embodiments, the length of the body of material 6 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 6 is formed from filamentary tow. In the present example, the tow used in the body of material 6 has a denier per filament (d.p.f.) of 8.4 and a total denier of 21,000. Alternatively, the tow can, for instance, have a denier per filament (d.p.f.) of 9.5 and a total denier of 12,000. Alternatively, the body of material 6 can have 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 5 plasticiser used in the tow comprises about 7% by weight of the tow. Alternatively, the plasticiser used in the tow comprises about 9% 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 6. For instance, rather than tow, the body 6 can be formed from paper, for instance in a similar way to paper filters known for use in cigarettes. Alternatively, the body 6 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, more preferably at least 6 and still more preferably at least 7. These values of denier per filament provide a tow which has relatively coarse, thick fibres with a lower surface area which result in a lower pressure drop across the mouthpiece 2 than tows having lower d.p.f. values. Preferably, to achieve a sufficiently uniform body of material 6, 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 10 d.p.f. In other examples, different materials can be used to form the body of material 6. For instance, rather than tow, the body 6 can be formed from paper, for instance in a similar way to paper filters known for use in cigarettes. For instance, the paper, or other cellulose-based material, can be provided as one or more portions of sheet material which is folded and/or crimped to form body 6. The sheet material can have a basis weight of from 15 gsm to 60 gsm, for instance between 20 and 50 gsm. The sheet material can, for instance, have a basis weight in any of the ranges between 15 and 25 gsm, between 25 and 30 gsm, between 30 and 40 gsm, between 40 and 45 gsm and between 45 and 50 gsm. Additionally or alternatively, the sheet material can have a width of between 50 mm and 200 mm, for instance between 60 mm and 150 mm, or between 80 mm and 150 mm. For instance, the sheet material can have a basis weight of between 20 and 50 gsm and a width between 80 mm and 150 mm. This can, for instance, enable the cellulose-based bodies to have appropriate pressure drops for an article having dimensions as described herein.
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 6, 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 10 d.p.f.
The total denier of the tow forming the body of material 6 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 2 which results in a lower pressure drop across the mouthpiece 2 than tows having higher total denier values. For appropriate firmness of the body of material 6, 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. More preferably, the denier per filament is between 6 and 10 while the total denier is between 11,000 and 22,000. 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.
The cross section of the filaments of tow may have an isoperimetric ratio L2/A of 25 or less, 20 or less, or 15 or less, where L is the length of the perimeter of the cross section and A is the area of the cross section. Such filaments of tow have a relatively low surface area for a given value of denier per filament, which improves delivery of aerosol to the consumer.
It is known to generate, for a given tow specification (such as 8.4Y21000), a tow capability curve which represents the pressure drop through a length of rod formed using the tow, for each of a range of tow weights. Parameters such as the rod length and circumference, wrapper thickness and tow plasticiser level are specified, and these are combined with the tow specification to generate the tow capability curve, which gives an indication of the pressure drop which would be provided by different tow weights between the minimum and maximum weights achievable using standard filter rod forming machinery. Such tow capability curves can be calculated, for instance, using software available from tow suppliers. It has been found that it is particularly advantageous to use a body of material 6 which includes filamentary tow having a weight per mm of length of the body of material 6 which is between about 10% and about 30% of the range between the minimum and maximum weights of a tow capability curve generated for the filamentary tow. This can provide an acceptable balance between providing enough tow weight to avoid shrinkage after the body 6 has been formed, providing an acceptable pressure drop, while also assisting with capsule placement within the tow, for capsules of the sizes described herein.
In some embodiments, and irrespective of the material used to form the body 6, the pressure drop across body 6, can, for instance, be between 0.3 and 5 mmWG per mm of length of the body 6, for instance between 0.5 mmWG and 2 mmWG per mm of length of the body 6. 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 6 can, for instance, be between 3 mmWG and 8 mWG, or between 4 mmWG and 7 mmWG. The total pressure drop across body 6 can be about 5, 6 or 7 mmWG.
Preferably, the length of the tubular portion 4a is less than about 50 mm. More preferably, the length of the tubular portion 4a is less than about 40 mm. Still more preferably, the length of the tubular portion 4a is less than about 30 mm. In addition, or as an alternative, the length of the tubular portion 4a is preferably at least about 10 mm. Preferably, the length of the tubular portion 4a is at least about 12 mm or at least about 15 mm. In some preferred embodiments, the length of the tubular portion 4a is from about 15 mm to about 35 mm, more preferably from about 20 mm to about 30 mm, even more preferably from about 22 to about 28 mm or 23 to 27 mm, or 24 to 26 mm, and, most preferably about 25 mm. In the present example, the length of the tubular portion 4a is 25 mm. In some embodiments, the length of the tubular portion 4a is from about 12 mm to about 20 mm, more preferably from about 15 mm to 19 mm or from about 16 mm to about 19 mm.
Preferably, the second plug wrap 9 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 45 gsm. Preferably, the second plug wrap 9 has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The second plug wrap 9 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 9 can be a porous plug wrap, for instance having a permeability of greater than 200 Coresta Units.
The tubular portion 4a is located around and defines an air gap within the mouthpiece 2 which acts as a cooling segment. The air gap provides a chamber through which heated volatilised components generated by the aerosol generating material 3 flow. The tubular portion 4a 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 1 is in use. The tubular portion 4a provides a physical displacement between the aerosol generating material 3 and the body of material 6. The physical displacement provided by the tubular portion 4a will provide a thermal gradient across the length of the tubular portion 4a.
Preferably, the mouthpiece 2 comprises a cavity having an internal volume greater than 110 mm3 and, preferably, at least 115 mm3. Providing a cavity of at least this volume has been found to enable the formation of an improved aerosol. More preferably, the mouthpiece 2 comprises a cavity, for instance formed within the tubular portion 4a (for instance by the channel), having an internal volume greater than 110 mm3 of at least 115 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. In some embodiments, the volume of the cavity is at least 125 mm3.
In some embodiments, the mouthpiece 2 comprises a cavity having an internal volume greater than 450 mm3. Providing a cavity of at least this volume has been found to enable the formation of an improved aerosol, such a cavity size provides sufficient space within the mouthpiece 2 to allow heated volatilised components to cool, therefore allowing the exposure of the aerosol generating material 3 to higher temperatures than would otherwise be possible, since they may result in an aerosol which is too warm. In the present example, the cavity is formed by the tubular portion 4a, but in alternative arrangements it could be formed within a different part of the mouthpiece 2. More preferably, the mouthpiece 2 comprises a cavity, for instance formed within the tubular portion 4a, having an internal volume greater than 500 mm3, and still more preferably greater than 550 mm3, allowing further improvement of the aerosol. In some examples, the internal cavity comprises a volume of between about 550 mm3 and about 750 mm3, for instance about 600 mm3 or 700 mm3.
The tubular portion 4a 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 tubular portion 4a and a heated volatilised component exiting a second, downstream end of the tubular portion 4a. The tubular portion 4a 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 tubular portion 4a and a heated volatilised component exiting a second, downstream end of the tubular portion 4a. This temperature differential across the length of the tubular portion 4a protects the temperature sensitive body of material 6 from the high temperatures of the aerosol generating material 3 when it is heated.
In alternative articles, the tubular portion 4a can be replaced with an alternative cooling element, for instance an element formed from a body of material which allows aerosol to pass through it longitudinally, and which also performs the function of cooling the aerosol.
The mouthpiece 2 of the article 1 comprises an upstream end 3a adjacent to the aerosol generating substrate 3 and a downstream end 2b distal from the aerosol generating substrate 3.
The pressure drop or difference (also referred to a resistance to draw) across the mouthpiece, for instance the part of the article 1 downstream of the aerosol generating material 3, is preferably less than about 40mmH2O. Such pressure drops have been found to allow sufficient aerosol, including desirable compounds such as flavour compounds, to pass through the mouthpiece 2 to the consumer. More preferably, the pressure drop across the mouthpiece 2 is less than about 32mmH2O. In some embodiments, particularly improved aerosol has been achieved using a mouthpiece 2 having a pressure drop of less than 31 mmH2O, for instance about 29 mmH2O, about 28 mmH2O or about 27.5 mmH2O. Alternatively or additionally, the mouthpiece pressure drop can be at least 10 mmH2O, preferably at least 15 mmH2O and more preferably at least 20 mmH2O. In some embodiments, the mouthpiece pressure drop can be between about 15 mmH2O and 40 mmH2O. These values enable the mouthpiece 2 to slow down the aerosol as it passes through the mouthpiece 2 such that the temperature of the aerosol has time to reduce before reaching the downstream end 2b of the mouthpiece 2.
In some embodiments, the aerosol-generating material has a packing density of between about 400 mg/cm3 and about 800 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 aerosol-generating material may not effectively grip the aerosol-generator of the aerosol provision.
In some embodiments, at least about 70% of a volume of the aerosol-generating section is filled with the aerosol-generating material. In some embodiments, from about 75% to about 85% of the volume of the cavity is filled with the aerosol-generating material.
In the present example, the aerosol generating material 3 is wrapped in a wrapper 10. The wrapper 10 can, for instance, be a paper or paper-backed foil wrapper. The wrapper 10 may be a moisture impermeable wrapper 10.
In the present example, the wrapper 10 is substantially impermeable to air. In alternative embodiments, the wrapper 10 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, results in an improvement in the aerosol formation in the aerosol generating material 3. Without wishing to be bound by theory, it is hypothesised that this is due to reduced loss of aerosol compounds through the wrapper 10. 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.
In the present embodiment, the wrapper 10 comprises aluminium foil. In other embodiments, the wrapper 10 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 material 3. 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 could have a backing formed from other materials, for instance to help provide an appropriate tensile strength to the foil, or it could 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 10 comprises paper or a paper backing, i.e. a cellulose based material, the wrapper can have a basis weight greater than about 30 gsm. For example, the wrapper can have a basis weight in the range from about 40 gsm to about 70 gsm. The inventors have advantageously found such basis weights provide an improved rigidity to the rod of aerosol-generating material. The improved rigidity provided by wrappers having a basis weight in this range can make the rod of aerosol-generating material 3 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 aerosol-generating material having increased rigidity can be beneficial where the plurality of strands or strips of aerosol-generating material 3 are aligned within the aerosol-generating section such that their longitudinal dimension is in parallel alignment with the longitudinal axis, since longitudinally aligned strands or strips of aerosol-generating material may provide less rigidity to the rod of aerosol generating material than when the strands or strips are not aligned. The improved rigidity of the rod of aerosol-generating material allows the article to withstand the increased forces to which the article is subject, in use.
In some embodiments, the moisture impermeable wrapper 10 is also substantially impermeable to air. In alternative embodiments, the wrapper 10 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 material 3. Without wishing to be bound by theory, it is hypothesised that this is due to reduced loss of aerosol compounds through the wrapper 10. 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
In other embodiments, the wrapper 10 surrounding the aerosol generating material 3 has a high level of permeability, for example greater than about 1000 Coresta Units, or greater than about 1500 Coresta Units, or greater than about 2000 Coresta Units. 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.
The wrapper 10 may be formed from a material with a high inherent level of permeability, an inherently porous material, or may be formed from a material with any level of inherent permeability where the final level of permeability is achieved by providing the wrapper 10 with a permeable zone or area. Providing a permeable wrapper 10 provides a route for air to enter the article. The wrapper 10 can be provided with a permeability such that the amount of air entering through the rod of aerosol generating material is relatively more than the amount of air entering the article through the ventilation holes 12 in the mouthpiece. An article having this arrangement may produce a more flavoursome aerosol which may be more satisfactory to the user.
In some embodiments, the wrapper 10 is a moisture impermeable wrapper 10 and can have a lower friction with the aerosol-generating material, which can result in strands and/or strips of aerosol-generating material being more easily displaced longitudinally, into the cooling section, when the aerosol generator is inserted into the rod of aerosol-generating material. The inventors have found that providing a tubular portion 4a directly adjacent to the source of aerosol generating material 3, and comprising an inner channel with a diameter in this range, advantageously reduces the longitudinal displacement of strands and/or strips of aerosol-generating material when the aerosol generator is inserted into the rod of aerosol-generating material. The inventors have found that 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.
In the present example, the aerosol-former material added to the aerosol generating substrate 3 comprises 14% by weight of the aerosol generating substrate 3. Preferably, the aerosol-former material comprises at least 5% by weight of the aerosol generating substrate, more preferably at least 10%. Preferably, the aerosol-former material comprises less than 25% by weight of the aerosol generating substrate, more preferably less than 20%, for instance between 10% and 20%, between 12% and 18% or between 13% and 16%.
Preferably the aerosol generating material 3 is provided as a cylindrical rod of aerosol generating material. Irrespective of the form of the aerosol generating material, it preferably has a length of about 10 mm to 100 mm. In some embodiments, the length of the aerosol generating material is preferably in the range about 25 mm to 50 mm, more preferably in the range about 30 mm to 45 mm, and still more preferably about 30 mm to 40 mm.
In some examples, the article 1 may be configured such that there is a separation (i.e. a minimum distance) between a heater of the non-combustible aerosol provision device 100 and the tubular body 4a. This prevents heat from the heater from damaging the material forming the tubular body 4a.
The minimum distance between a heater of the non-combustible aerosol provision device 100 and the tubular body 4a may be 3 mm or greater. In some examples, minimum distance between the heater of the non-combustible aerosol provision device 100 and the tubular body 4a may be in the range 3 mm to 10 mm, for example 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm or 10 mm.
The separation between the heater of the non-combustible aerosol provision device 100 and the tubular body 4a may be achieved by, for example, adjusting the length of the rod of aerosol generating material 3.
The volume of aerosol generating material 3 provided can vary from about 200 mm3 to about 4300 mm3, preferably from about 500 mm3 to 1500 mm3, more preferably from about 1000 mm3 to about 1300 mm3. The provision of these volumes of aerosol generating material, for instance from about 1000 mm3 to about 1300 mm3, has been advantageously shown to achieve a superior aerosol, having a greater visibility and sensory performance compared to that achieved with volumes selected from the lower end of the range.
The mass of aerosol generating material 3 provided can be greater than 200 mg, for instance from about 200 mg to 400 mg, preferably from about 230 mg to 360 mg, more preferably from about 250 mg to 360 mg. It has been advantageously found that providing a higher mass of aerosol generating material results in improved sensory performance compared to aerosol generated from a lower mass of tobacco material.
Preferably the aerosol generating material or substrate is formed from tobacco material as described herein, which includes a tobacco component.
In the tobacco material described herein, the tobacco component preferably contains paper reconstituted tobacco. The tobacco component may also contain leaf tobacco, extruded tobacco, and/or bandcast tobacco.
The aerosol generating material 3 can comprise reconstituted tobacco material having a density of less than about 700 milligrams per cubic centimetre (mg/cc). Such tobacco material has been found to be particularly effective at providing an aerosol generating material which can be heated quickly to release an aerosol, as compared to denser materials. For instance, the inventors tested the properties of various aerosol generating materials, such as bandcast reconstituted tobacco material and paper reconstituted tobacco material, when heated. It was found that, for each given aerosol generating material, there is a particular zero heat flow temperature below which net heat flow is endothermic, in other words more heat enters the material than leaves the material, and above which net heat flow is exothermic, in other words more heat leaves the material than enters the material, while heat is applied to the material. Materials having a density less than 700 mg/cc had a lower zero heat flow temperature. Since a significant portion of the heat flow out of the material is via the formation of aerosol, having a lower zero heat flow temperature has a beneficial effect on the time it takes to first release aerosol from the aerosol generating material. For instance, aerosol generating materials having a density of less than 700 mg/cc were found to have a zero heat flow temperature of less than 164° C., as compared to materials with a density over 700 mg/cc, which had zero heat flow temperatures greater than 164° C.
The density of the aerosol generating material also has an impact on the speed at which heat conducts through the material, with lower densities, for instance those below 700 mg/cc, conducting heat more slowly through the material, and therefore enabling a more sustained release of aerosol.
Preferably, the aerosol generating material 3 comprises reconstituted tobacco material having a density of less than about 700 mg/cc, for instance paper reconstituted tobacco material. More preferably, the aerosol generating material 3 comprises reconstituted tobacco material having a density of less than about 600 mg/cc. Alternatively or in addition, the aerosol generating material 3 preferably comprises reconstituted tobacco material having a density of at least 350 mg/cc, which is considered to allow for a sufficient amount of heat conduction through the material.
The tobacco material may be provided in the form of cut rag tobacco. The cut rag tobacco can have a cut width of at least 15 cuts per inch (about 5.9 cuts per cm, equivalent to a cut width of about 1.7 mm). Preferably, the cut rag tobacco has a cut width of at least 18 cuts per inch (about 7.1 cuts per cm, equivalent to a cut width of about 1.4 mm), more preferably at least 20 cuts per inch (about 7.9 cuts per cm, equivalent to a cut width of about 1.27 mm). In one example, the cut rag tobacco has a cut width of 22 cuts per inch (about 8.7 cuts per cm, equivalent to a cut width of about 1.15 mm). Preferably, the cut rag tobacco has a cut width at or below 40 cuts per inch (about 15.7 cuts per cm, equivalent to a cut width of about 0.64 mm). Cut widths between 0.5 mm and 2.0 mm, for instance between 0.6 mm and 1.5 mm, or between 0.6 mm and 1.7 mm have been found to result in tobacco material which is preferably in terms of surface area to volume ratio, particularly when heated, and the overall density and pressure drop of the substrate 3. The cut rag tobacco can be formed from a mixture of forms of tobacco material, for instance a mixture of one or more of paper reconstituted tobacco, leaf tobacco, extruded tobacco and bandcast tobacco. Preferably the tobacco material comprises paper reconstituted tobacco or a mixture of paper reconstituted tobacco and leaf tobacco.
In the tobacco material described herein, the tobacco material may contain a filler component. The filler component is generally a non-tobacco component, that is, a component that does not include ingredients originating from tobacco. The filler component may be a non-tobacco fibre such as wood fibre or pulp or wheat fibre. The filler component may also be an inorganic material such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material. The filler component may be present in an amount of 0 to 20% by weight of the tobacco material, or in an amount of from 1 to 10% by weight of the composition. In some embodiments, the filler component is absent.
In the tobacco material described herein, the tobacco material contains an aerosol-former material. In this context, an “aerosol-former material” is an agent that promotes the generation of an aerosol. An aerosol-former material may promote the generation of an aerosol by promoting an initial vaporisation and/or the condensation of a gas to an inhalable solid and/or liquid aerosol. In some embodiments, an aerosol-former material may improve the delivery of flavour from the aerosol generating material. In general, any suitable aerosol-former material or agents may be included in the aerosol generating material of the present disclosure, including those described herein. Other suitable aerosol-former materials include, but are not limited to: a polyol such as sorbitol, glycerol, and glycols like propylene glycol or triethylene glycol; a non-polyol such as monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate or myristates including ethyl myristate and isopropyl myristate and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate. In some embodiments, the aerosol-former material may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. Glycerol may be present in an amount of from 10 to 20% by weight of the tobacco material, for example 13 to 16% by weight of the composition, or about 14% or 15% by weight of the composition. Propylene glycol, if present, may be present in an amount of from 0.1 to 0.3% by weight of the composition.
The aerosol-former material may be included in any component, for example any tobacco component, of the tobacco material, and/or in the filler component, if present. Alternatively or additionally the aerosol-former material may be added to the tobacco material separately. In either case, the total amount of the aerosol-former material in the tobacco material can be as defined herein.
The tobacco material can contain between 10% and 90% by weight tobacco leaf, wherein the aerosol-former material is provided in an amount of up to about 10% by weight of the leaf tobacco. To achieve an overall level of aerosol-former material between 10% and 20% by weight of the tobacco material, it has been advantageously found that this can be added in higher weight percentages to the another component of the tobacco material, such as reconstituted tobacco material.
The tobacco material described herein contains nicotine. The nicotine content is from 0.5 to 1.75% by weight of the tobacco material, and may be, for example, from 0.8 to 1.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material contains between 10% and 90% by weight tobacco leaf having a nicotine content of greater than 1.5% by weight of the tobacco leaf. It has been advantageously found that using a tobacco leaf with nicotine content higher than 1.5% in combination with a lower nicotine base material, such as paper reconstituted tobacco, provides a tobacco material with an appropriate nicotine level but better sensory performance than the use of paper reconstituted tobacco alone. The tobacco leaf, for instance cut rag tobacco, can, for instance, have a nicotine content of between 1.5% and 5% by weight of the tobacco leaf.
The tobacco material described herein can contain an aerosol modifying agent, such as any of the flavours described herein. In one embodiment, the tobacco material contains menthol, forming a mentholated article. The tobacco material can comprise from 3 mg to 20 mg of menthol, preferably between 5 mg and 18 mg and more preferably between 8 mg and 16 mg of menthol. In the present example, the tobacco material comprises 16 mg of menthol. The tobacco material can contain between 2% and 8% by weight of menthol, preferably between 3% and 7% by weight of menthol and more preferably between 4% and 5.5% by weight of menthol. In one embodiment, the tobacco material includes 4.7% by weight of menthol. Such high levels of menthol loading can be achieved using a high percentage of reconstituted tobacco material, for instance greater than 50% of the tobacco material by weight. Alternatively or additionally, the use of a high volume of aerosol generating material, for instance tobacco material, can increase the level of menthol loading that can be achieved, for instance where greater than about 500 mm3 or suitably more than about 1000 mm3 of aerosol generating material, such as tobacco material, are used.
In the compositions described herein, where amounts are given in % by weight, for the avoidance of doubt this refers to a dry weight basis, unless specifically indicated to the contrary. Thus, any water that may be present in the tobacco material, or in any component thereof, is entirely disregarded for the purposes of the determination of the weight %. The water content of the tobacco material described herein may vary and may be, for example, from 5 to 15% by weight. The water content of the tobacco material described herein may vary according to, for example, the temperature, pressure and humidity conditions at which the compositions are maintained. The water content can be determined by Karl-Fisher analysis, as known to those skilled in the art. On the other hand, for the avoidance of doubt, even when the aerosol-former material is a component that is in liquid phase, such as glycerol or propylene glycol, any component other than water is included in the weight of the tobacco material. However, when the aerosol-former material is provided in the tobacco component of the tobacco material, or in the filler component (if present) of the tobacco material, instead of or in addition to being added separately to the tobacco material, the aerosol-former material is not included in the weight of the tobacco component or filler component, but is included in the weight of the “aerosol-former material” in the weight % as defined herein. All other ingredients present in the tobacco component are included in the weight of the tobacco component, even if of non-tobacco origin (for example non-tobacco fibres in the case of paper reconstituted tobacco).
In an embodiment, the tobacco material comprises the tobacco component as defined herein and the aerosol-former material as defined herein. In an embodiment, the tobacco material consists essentially of the tobacco component as defined herein and the aerosol-former material as defined herein. In an embodiment, the tobacco material consists of the tobacco component as defined herein and the aerosol-former material as defined herein.
Paper reconstituted tobacco is present in the tobacco component of the tobacco material described herein in an amount of from 10% to 100% by weight of the tobacco component. In embodiments, the paper reconstituted tobacco is present in an amount of from 10% to 80% by weight, or 20% to 70% by weight, of the tobacco component. In a further embodiment, the tobacco component consists essentially of, or consists of, paper reconstituted tobacco. In preferred embodiments, leaf tobacco is present in the tobacco component of the tobacco material in an amount of from at least 10% by weight of the tobacco component. For instance, leaf tobacco can be present in an amount of at least 10% by weight of the tobacco component, while the remainder of the tobacco component comprises paper reconstituted tobacco, bandcast reconstituted tobacco, or a combination of bandcast reconstituted tobacco and another form of tobacco such as tobacco granules.
Paper reconstituted tobacco refers to tobacco material formed by a process in which tobacco feedstock is extracted with a solvent to afford an extract of solubles and a residue comprising fibrous material, and then the extract (usually after concentration, and optionally after further processing) is recombined with fibrous material from the residue (usually after refining of the fibrous material, and optionally with the addition of a portion of non-tobacco fibres) by deposition of the extract onto the fibrous material. The process of recombination resembles the process for making paper.
The paper reconstituted tobacco may be any type of paper reconstituted tobacco that is known in the art. In a particular embodiment, the paper reconstituted tobacco is made from a feedstock comprising one or more of tobacco strips, tobacco stems, and whole leaf tobacco. In a further embodiment, the paper reconstituted tobacco is made from a feedstock consisting of tobacco strips and/or whole leaf tobacco, and tobacco stems. However, in other embodiments, scraps, fines and winnowings can alternatively or additionally be employed in the feedstock.
The paper reconstituted tobacco for use in the tobacco material described herein may be prepared by methods which are known to those skilled in the art for preparing paper reconstituted tobacco.
In some embodiments, it can be particularly advantageous to use a hollow tubular element 8 having a length of greater than about 10 mm, for instance between about 10 mm and about 30 mm or between about 12 mm and about 25 mm. It has been found that a consumer's lips are likely to extend in some cases to about 12 mm from the mouth end of the article 1 when drawing aerosol through the article 1, and therefore a hollow tubular element 8 having a length of at least 10 mm or at least 12 mm means that most of the consumer's lips surround this element 8.
Preferably, the length of the body of material 6 is less than about 15 mm. More preferably, the length of the body of material 6 is less than about 10 mm. In addition, or as an alternative, the length of the body of material 6 is at least about 5 mm.
Preferably, the length of the body of material 6 is at least about 6 mm. In some preferred embodiments, the length of the body of material 6 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.
The part of the mouthpiece which comes into contact with a consumer's lips has usually been a paper tube, which is either hollow or surrounds a cylindrical body of filter material. Providing a hollow tubular element 8 has advantageously been found to significantly reduce the temperature of the outer surface of the mouthpiece 2′ at the downstream end 2b of the mouthpiece which comes into contact with a consumer's mouth when the article 1′ is in use. In addition, the use of the tubular portion 4a has also been found to significantly reduce the temperature of the outer surface of the mouthpiece 2′ even upstream of the tubular portion 4a. Without wishing to be bound by theory, it is hypothesised that this is due to the tubular portion 4a channelling aerosol closer to the centre of the mouthpiece 2′, and therefore reducing the transfer of heat from the aerosol to the outer surface of the mouthpiece 2′.
In addition, the increased thickness of the wall 4b of the tubular portion 4a means that it has a greater thermal mass, which has been found to be effective at reducing the temperature of the aerosol passing through the tubular portion 4a and reducing the surface temperature of the mouthpiece 2 at locations downstream of the tubular portion 4a, due to the increased thickness of the tubular portion 4a channelling the aerosol centrally within the mouthpiece 2, 2′ such that less heat from the aerosol is transferred to the outer portions of the mouthpiece 2, 2′ such as outer portions of the body of material 6. In some embodiments, the thickness of the wall 4b of the tubular portion 4a is at least 325 microns and, preferably, at least 400, 500, 600, 700, 800, 900, 1000, 1250 or 1500 microns.
In addition, it has been found that the relatively high permeability of the tubular portion 4a increases the amount of heat that is transferred to the tubular portion 4a from the aerosol and thus reduces the temperature of the aerosol. The permeability of the tubular portion 4a has also been found to increase the amount of moisture that is transferred from the aerosol to the tubular portion 4a, which has been found to improve the feel of the aerosol in the user's mouth. A high permeability of tubular portion 4a also results makes it easier to cut the ventilation holes 12 using a laser, meaning that a lower power of laser can be used. In some embodiments, the permeability of the tubular portion 4a is at least 100 Coresta Units and, preferably, at least 500 Coresta Units, at least 1000 Coresta Units or at least 2000 Coresta Units.
In the present example hollow tubular element 8 is formed from filamentary tow. In alternative embodiments the hollow tubular element may be formed using any construction as described herein for the tubular portion 4a.
The “wall thickness” of the hollow tubular element 8 corresponds to the thickness of the wall of the tube 8 in a radial direction. This may be measured in the same way as that of the tubular portion. 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 8. 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 8, more preferably 1.0 mm or greater.
Preferably, the length of the hollow tubular element 8 is less than about 20 mm. More preferably, the length of the hollow tubular element 8 is less than about 15 mm. Still more preferably, the length of the hollow tubular element 8 is less than about 10 mm. In addition, or as an alternative, the length of the hollow tubular element 8 is at least about 5 mm. Preferably, the length of the hollow tubular element 8 is at least about 6 mm. In some preferred embodiments, the length of the hollow tubular element 8 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 8 is 6 mm.
Preferably, the density of the hollow tubular element 8 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 8 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 8 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 disclosure, the “density” of the hollow tubular element 8 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 8 by the total volume of the hollow tubular element 8, wherein the total volume can be calculated using appropriate measurements of the hollow tubular element 8 taken, for example, using callipers. Where necessary, the appropriate dimensions may be measured using a microscope.
The filamentary tow forming the hollow tubular element 8 preferably has a total denier 10) of less than 45,000, more preferably less than 42,000. This total denier has been found to allow the formation of a hollow tubular element 8 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 8 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 8 preferably has a denier per filament of greater than 3. This denier per filament has been found to allow the formation of a hollow tubular element 8 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 8 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 8 has an 8Y40,000 tow formed from cellulose acetate and comprising 18% plasticiser, for instance triacetin. In another 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 8 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 2′ to the consumers 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 8 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 8 is about 3.9 mm.
The hollow tubular element 8 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 hollow tubular element 8 comprises from 16% to 20% by weight of plasticiser, for instance about 17%, about 18% or about 19% plasticiser.
In the present example the tubular portion 4a is a first hollow tubular element, and hollow tubular element 8 is a second hollow tubular element.
In the present example the ventilation is provided into tubular portion 4a, as described in relation to
In the examples described above, the mouthpieces 2, 2′ each comprise a single body of material 6. In other examples, the mouthpiece 2, 2′ may include multiple bodies of material. The mouthpieces 2, 2′ may comprise a cavity between the bodies of material.
The article 1, 1′ comprises first and second wrappers 9, 5. In the present example, the first wrapper is the second plug wrap 9 and the second wrapper is the tipping paper 5.
The first wrapper 9 comprises a sheet material with a plurality of formations which, in the present example, are lines of strength discontinuity resulting in non-uniformity in the curvature of at least a portion of the first wrapper. The second wrapper 5 overlies at least a portion of the first wrapper 9. The formations may be continuous or discontinuous.
In some embodiments, the first wrapper 9 comprises paper. However, it should be recognised that the first wrapper 9 may alternatively comprise a different material, for example, plastic or foil, including a metallic foil such as aluminium foil.
Referring now to
In the present example, the lines of strength discontinuity 201 are lines of weakness 201. The lines of weakness 201 are formed on the side of the sheet material 201 that forms an inwardly facing surface of the first wrapper 9. However, in an alternative embodiment the lines of weakness 201 are instead formed on the side of the sheet material 201 that forms a radially outwardly facing surface of the first wrapper 9. As illustrated in
In some embodiments, the first wrapper 9 comprises foil and the lines of strength discontinuity are laser-cut into the foil. However, it should be recognised that the lines of strength discontinuity may be formed in the foil by other means, for example, a different cutting device or being pin embossed.
As shown in
The sheet material 200 is rolled up around a component, for example, the of body of material 6 and/or tubular portion 4a and/or tubular element 8 to form the first wrapper 9. Peripheral edges 9a, 9b of the first wrapper 9 may be glued to one another in an overlapping joint.
As illustrated in
It will be appreciated that the shape of the facets 202 can be selected depending on the pattern of the lines of weakness 201. In the example illustrated in
In some embodiments, the sheet material of the first wrapper has a thickness in the range of 20 to 200 microns and, preferably, in the range of 50 to 115 microns. In some embodiments, the sheet material of the first wrapper has a basis weight of above 40, 45, 50, 55, 60, 70, 80 and 90 gsm. However, a skilled person will recognise that other thicknesses and basis weights of the sheet material are possible. As discussed above, the sheet material may comprise paper and/or an alternative material such as a sheet of foil or plastic.
It has been found that increasing the basis weight of the sheet material of the first wrapper 9 reduces heat transfer through the first wrapper 9 and thus promotes a lower temperature of the exterior of the article 1, 1′ and, in particular, of the mouthpiece 2, 2′. In some embodiments, the sheet material of the first wrapper 9 has a basis weight of at least 50 gsm and, preferably, at least 60, 70, 80, 90, 100, 110 or 120 gsm.
In some embodiments, the first wrapper 9 is a plug wrap and has a basis weight in the range of 70 to 120 gsm and, preferably, in the range of 80 to 110 gsm.
In some embodiments, the first wrapper 9 is a tipping paper and has a basis weight in the range of 40 to 80 gsm and, preferably, in the range of 50 to 70 gsm.
Referring to
The facets 202 may have a closed perimeter which may be curved or polyogonal in shape, or the facets may have an open shape such as parallel strips extending between spaced, parallel lines of weakness, for example extending longitudinally as illustrated in the second array 205 in
Also, as illustrated in
The gaps 206 help to thermally insulate the second wrapper 5 from the first wrapper 9 to reduce the temperature of the second wrapper 5 during the generation of aerosol. When heated aerosol passes through the mouthpiece 2, 2′, the aerosol transfers heat into the mouthpiece and this warms the outer surface of the mouthpiece, including the area which comes into contact with the consumers lips during use, which in the present example is the second wrapper 5, which optionally is the tipping paper 5. The mouthpiece 2, 2′ temperature may be higher than consumers are accustomed to when smoking, for instance, conventional cigarettes, and this can be an undesirable effect.
The gaps 205 thus help to alleviate this effect by reducing the temperature of the second wrapper 5.
In some embodiments, the sheet material is disposed in a tubular configuration.
In some embodiments, longitudinal side edges of the sheet material are disposed in a butt joint.
In some embodiments, a first array of facets of a first shape are arranged in a first array in a first portion of the sheet material and a second array of facets of a second different shape from the first facets are arranged in a second array in a second portion of the sheet material. In some embodiments, opposite edges of the wrapper have a shape defined by the edges of the facets such that when wrapped to abut one another, the opposite edges of the sheet form a butt joint against one another such that the array extends across the butt joint.
It should be recognised that in one alternative embodiment (not shown), the second wrapper 5 is covered by a further wrapper (not shown). The further wrapper may be a tipping paper instead of the second wrapper 5. The reduced temperature of the second wrapper 5 due to the gaps 205 will result in a reduced temperature of the further wrapper.
In
In one example of manufacture, the sheet material 200 is supplied to as a continuous web (not shown) by means of supply rollers (not shown) through a station (not shown) where the lines of strength discontinuity are formed. The station 1 may include one or more lasers that produce the lines of weakness 201 across the web. Alternatively the station may include blades to cut the paper web on one or both sides to form the lines 201, or an arrangement to crease the paper web to form the lines of weakness 201. The web after leaving the station may be fed into a take up roll (not shown) which is then taken to an article making machine for incorporation into a articles for non-combustible aerosol provision systems. Thus the paper is prepared off-line from the article making machine in a preparatory process. Alternatively, the web and the station may be provided on-line at the article making machine for forming the lines of weakness in the web just before it is supplied into the making machine.
Another example of a mouthpiece 2 shown in
The mouthpiece optionally includes an underlying support layer 303 to which the first wrapper 9 may be affixed by gluing or other suitable means evident to those skilled in the art. The support layer 303 may comprise a rectangular, rolled blank of sheet material such as paper support layer 21 may be glued to the body of material 6 and/or tubular portion 4a and/or tubular element 8.
In the example shown in
In the example shown in
The non-uniformity of the curvature of the first wrapper 9 caused by the lines of strength discontinuity 301 means that the second wrapper 5 that overlies the first wrapper 9 has a curvature that does not correspond to that of the first wrapper 9. Thus, gaps 306 are formed between the first and second wrappers 9, 5. In the present example, gaps 306 are formed between the facets 302 of the first wrapper 9 and an inner surface 307 of the second wrapper 5.
The gaps 306 help to thermally insulate the second wrapper 5 from the first wrapper 9 to reduce the temperature of the second wrapper 5 during the generation of aerosol.
In some embodiments, the lines of strength discontinuity are continuous. In other embodiments, the lines of strength discontinuity are discontinuous.
In alternative embodiments (not shown), the formations 201, 301, for example, lines of strength discontinuity 201, 301, can be formed on the outside surface of the first wrapper to achieve the facets 202, 302. The production of the lines of strength discontinuity 201, 301 may involve burning the sheet material 200, 300.
In some embodiments, the one or more gaps are configured to permit the flow of ventilation air. The flow of ventilation air helps to lower the temperature of the exterior of the article.
In some embodiments, the formations are configured to form one or more channels (not shown). The gaps may form the channels. Or the gaps may be provided in addition to the channels (for example, on opposite sides of the wrapper). The or each channel may be configured to permit the flow of ventilation air. The flow of ventilation air helps to lower the temperature of the exterior of the article.
The or each channel may be formed between the first wrapper and a component of the article and, preferably, comprises a groove in the first wrapper. For instance, the channel(s) may be formed between the first and second wrappers 9, 5.
In some embodiments, the or each channel extends towards a mouth end of the article such that ventilation air can enter the channel and flow towards the mouth end. Thus, ventilation flow can enter the channel(s) and flow towards the mouth end of the article. In some embodiments, the or each channel extends to the mouth end of the article. Thus, ventilation flow can enter the channel(s) and flow towards the mouth end of the article to exit at the mouth end.
In some embodiments, the or each channel extends substantially parallel to the central axis of the article.
In some embodiments, the article comprises a ventilation zone that overlies at least a part of the channel(s). For example, the ventilation zone may be provided in the second wrapper 5.
In some embodiments, the ventilation zone may comprise perforations in the outer layer of the wrappers such that the ventilation air can flow through the perforations to enter the gaps, for instance, to enter the channels. Alternatively, or additionally, the ventilation zone may comprise a permeable wrapper or permeable area of wrapper. For the lighter weight papers, i.e. 20 gsm to 40 gsm when used as the sheet material 200, 300, a structural coating such as a varnish can be applied e.g. by printing onto the paper to rigidify the paper and thereby define the facets. This could be printed on the inside or outside of the first wrapper 9. Alternatively, the varnish can be printed in lines to form borders around the facets.
Also, the lines of strength discontinuity need not be lines of weakness and can be lines of strength formed for example by printing patterns of a structural coating such as starch or varnish onto the sheet material 200, 300 in order to produce local stiffening.
Another example of a mouthpiece 2 shown in
The sheet material 400 is rolled about a body of material 6 and/or tubular portion 4a and/or tubular element 8 to form a first wrapper 9. In the present example, the first wrapper 9 is applied to the mouthpiece 2 of the article 1 of
The mouthpiece optionally includes an underlying support layer 403 to which the first wrapper 9 may be affixed by gluing or other suitable means evident to those skilled in the art. The support layer 403 may comprise a rectangular, rolled blank of sheet material such as paper support layer and may be glued to the body of material 6 and/or tubular portion 4a and/or tubular element 8.
The protuberances 401 may be formed on one or both sides of the sheet material.
In some embodiments, the protuberances 401 are arranged in a regular repeating pattern.
In the example shown in
In the present example, the formations 401 form facets 402 that are generally planar. However, it should be recognised that in alternative embodiments (not shown) the formations 401 have a different configuration, for example, being generally convex or concave.
In the present example, the formations 401 are generally square. However, in alternative embodiments (not shown), the formations 401 may be a different shape, for example, rectangular, circular, oval, triangular, or hexagonal. The formations 401 may be all the same shape or at least one of the formations 401 may be a different shape to the remaining formations 401.
In the present example, the formations 401 are all the same size. However, in alternative embodiments (not shown) at least one of the formations 401 is a different size to the remaining formations 401.
In the present example, the formations 401 project outwardly from an outer surface of the sheet material of the first wrapper 9 such that the protrusions 401 abut the second wrapper 5. The protrusions 401 present a non-uniformity in the curvature of the first wrapper 9 such that one or more gaps 406 are formed in the space between the protrusions 401 such that part of the first wrapper 9 is spaced from the second wrapper 5. In the present example, a gap 406 is formed between each pair of adjacent protrusions 401.
The or each gap 406 helps to thermally insulate the second wrapper 5 from the first wrapper 9 to reduce the temperature of the second wrapper 5 during the generation of aerosol.
In an alternative embodiment (not shown), the protrusions 401 are formed on an inner surface of the sheet material such that the protrusions 401 abut a component that the first wrapper 9 circumscribes. For instance, the protrusions 401 may abut the first plug wrap 7 that circumscribes the body of material 6, or directly abut the body of material 6 (in which case the first wrapper 9 may be the first plug wrap 7 of the body of material 6), and/or abut the tubular portion 4a. The inwardly directed protrusions 401 present a non-uniformity in the curvature of the inner surface of the first wrapper 9 such that one or more gaps are formed in the space between the protrusions 401 such that part of the first wrapper 9 is spaced from the component that the protrusions 401 abut. As before, the or each gap 406 helps to thermally insulate the second wrapper 5 from the first wrapper 9 to reduce the temperature of the second wrapper 5 during the generation of aerosol.
In one embodiment (not shown), the formations 401 are provided on both sides of the sheet material 400 of the first wrapper 9.
In an alternative embodiment (not shown), the formations 401, or at least some of the formations 401, are in the form of depressions formed into the surface of the sheet material 400. The depressions may be dimples formed in the sheet material 400. The protrusions/depressions may be formed using an embossing tool.
Referring now to
The embossed formations 401, 501 may have the shape of the lines of weakness shown in any of
In some embodiments, the first and second wrappers 9, 5 are applied to an article 1, 1′ having a tubular portion 4a in the form of a paper tube 4a that has a thickness T as described elsewhere in this disclosure, for instance, at least 325 microns or at least 400, 500, 600, 700, 800, 900, 1000, 1250 or 1500 microns. However, this in other embodiments the paper tube 4a is omitted or has a different thickness T, for example, less than 325 microns.
In some embodiments, the first and second wrappers 9, 5 are applied to an article 1, 1′ having a tubular portion 4a in the form of a paper tube 4a that has a permeability as described elsewhere in this disclosure, for instance, at least 100 Coresta Units. However, this in other embodiments the paper tube 4a is omitted or has a different permeability, for example, less than 100 Coresta Units.
In some embodiments (not shown), the first and/or second wrapper 9, 5 is omitted. In some embodiments, the first wrapper 9 does not comprise lines of strength discontinuity.
Referring now to Tables 2 to 19 below, experimental data is shown providing surface temperature at three measurement points for ten samples of different configurations of article 1′. Each article 1′ is of the same configuration as shown in
The hollow tubular element 8 is provided at the mouth end, the body of material 6 is provided upstream of the hollow tubular element 8, the tubular portion 4a is provided upstream of the body of material 6, and the rod of aerosol generating material 3 is provided upstream of the tubular portion 4a. The tubular portion 4a, body of material 6 and hollow tubular element 8 are combined by the second plug wrap 9, which is wrapped around all three sections. The second plug wrap 9 has different configurations, and the effect of changing the parameters of the second plug wrap 9 on the exterior temperature of the article 1 was measured. More specifically, a first temperature sensor measures the temperature of the outer surface of the article 1′ at a first location 3 mm from the mouth end (the downstream end) of the article 1′ during use of the article 1′ using a smoking machine; a second temperature sensor measures the temperature of the outer surface of the article 1′ at a second location 8 mm from the mouth end of the article 1′; and, a third temperature sensor measures the temperature of the outer surface of the article 1′ at a third location 14 mm from the mouth end of the article 1′. Thus, the first, second and third temperature sensors measure the temperature at respective axial locations on the external surface of the tipping paper 5.
The different configurations of article 1′ are as follows:
Tables 1 to 3 relate to the temperature measurements of an article having 60% ventilation and comprising a 27 gsm second plug wrap that does not include formations for generating air gaps. Table 2 shows exterior temperature measurements taken at 3 mm from the mouth end, Table 3 shows exterior temperature measurements taken at 8 mm from the mouth end, and Table 4 shows exterior temperature measurements taken at 14 mm from the mouth end.
Tables 4 to 6 relate to the temperature measurements of an article having 75% ventilation and comprising a 27 gsm second plug wrap that does not include formations for generating air gaps. Table 5 shows exterior temperature measurements taken at 3 mm from the mouth end, Table 6 shows exterior temperature measurements taken at 8 mm from the mouth end, and Table 7 shows exterior temperature measurements taken at 14 mm from the mouth end.
Tables 7 to 9 relate to the temperature measurements of an article having 60% ventilation and comprising a 70 gsm second plug wrap that includes formations for generating air gaps. The formations are embossed protrusions arranged in a honeycomb pattern as depicted in
Tables 10 to 12 relate to the temperature measurements of an article having 75% ventilation and comprising a 70 gsm second plug wrap that includes formations for generating air gaps. The formations are embossed protrusions arranged in a honeycomb pattern as depicted in
Tables 13 to 15 relate to the temperature measurements of an article having 60% ventilation and comprising a 100 gsm second plug wrap that includes formations for generating air gaps. The formations are embossed protrusions arranged in a honeycomb pattern as depicted in
Tables 16 to 18 relate to the temperature measurements of an article having 75% ventilation and comprising a 100 gsm second plug wrap that includes formations for generating air gaps. The formations are embossed protrusions arranged in a honeycomb pattern as depicted in
In each of Tables 2 to 19, the temperature measurements are provided for ten different samples. The temperature at each measurement location is recorded for nine puffs of each sample, namely nine draws of the article 1′ using the smoking machine.
As can be observed from the above data, the provision of embossing on the first wrapper 9 helps to reduce the surface temperature measured at each of the three measurement points, namely 3 mm, 8 mm and 14 mm from the mouth end of the article 1, 1′. This is the case for both the 60% and 75% ventilation samples. Furthermore, it can be observed that the increased thickness of the 100 gsm sheet material promotes a lower surface temperature at each of the measurement points in comparison to the thinner 70 gsm sheet material and even thinner 27 gsm sheet material.
In some examples, the mouthpiece 2, 2′ downstream of the aerosol generating material 3 can comprise a wrapper, for instance the first or second plug wraps 7, 9, or tipping paper 5, which comprises an aerosol modifying agent as described herein or other sensate material. The aerosol modifying agent may be disposed on an inwardly or outwardly facing surface of the mouthpiece wrapper. For instance, the aerosol modifying agent or other sensate material may be provided on an area of the wrapper, such as an outwardly facing surface of the tipping paper 5, which comes into contact with the consumer's lips during use. By disposing the aerosol modifying agent or other sensate material on the outwardly facing surface of the mouthpiece wrapper, the aerosol modifying agent or other sensate material may be transferred to the consumer's lips during use. Transfer of the aerosol modifying agent or other sensate material to the consumer's lips during use of the article may modify the organoleptic properties (e.g. taste) of the aerosol generated by the aerosol generating substrate 3 or otherwise provide the consumer with an alternative sensory experience. For example, the aerosol modifying agent or other sensate material may impart flavour to the aerosol generated by the aerosol generating substrate 3. The aerosol modifying agent or other sensate material may be at least partially soluble in water such that it is transferred to the user via the consumer's saliva. The aerosol modifying agent or other sensate material may be one that volatilises by the heat generated by the aerosol provision system. This may facilitate transfer of the aerosol modifying agent to the aerosol generated by the aerosol generating substrate 3. A suitable sensate material may be a flavour as described herein, sucralose or a cooling agent such as menthol or similar. In other embodiments (not shown), the mouthpiece 2, 2′ additionally or alternatively comprises a capsule (not shown) comprising an aerosol modifying agent. The capsule may be located in the body 6.
In some embodiments, a non-combustible aerosol provision system is provided comprising an aerosol modifying component and a heater which, in use, is operable to heat the aerosol generating material 3 such that the aerosol generating material 3 provides an aerosol. The aerosol modifying component may comprise one or more aerosol modifying agents. The aerosol modifying agent is provided within the body of material 6, in the present example in the form of a capsule. Optionally, an oil-resistant first plug wrap surrounds the body of material 6. In other examples, the aerosol modifying agent can be provided in other forms, such as material injected into the body of material 6 or provided on a thread, for instance the thread carrying a flavourant or other aerosol modifying agent, which may also be disposed within the body of material 6.
The aerosol modifying component may comprise one or more capsules. The or each capsule can comprise a breakable capsule, for instance a capsule which has a solid, frangible shell surrounding a liquid payload. In some embodiments, a single capsule is used. In other embodiments, a plurality of capsules are used.
The or each capsule is entirely embedded within the body of material 6. In other words, the capsule is completely surrounded by the material forming the body 6. In other examples, a plurality of breakable capsules may be disposed within the body of material 6, for instance 2, 3 or more breakable capsules. The length of the body of material 6 can be increased to accommodate the number of capsules required. In examples where a plurality of capsules is used, the individual capsules may be the same as each other, or may differ from one another in terms of size and/or capsule payload. In other examples, multiple bodies of material 6 may be provided, with each body containing one or more capsules.
The or each capsule may have a core-shell structure. In other words, each capsule comprises a shell encapsulating a liquid agent, for instance a flavourant or other agent, which can be any one of the flavourants or aerosol modifying agents described herein. The shell of the capsule can be ruptured by a user to release the flavourant or other agent into the body of material 6. The first plug wrap can comprise a barrier coating to make the material of the plug wrap substantially impermeable to the liquid payload of the capsule. Alternatively or in addition, the second plug wrap 9 and/or tipping paper 5 can comprise a barrier coating to make the material of that plug wrap and/or tipping paper substantially impermeable to the liquid payload of the capsule.
In some embodiments, the or each capsule is spherical and has a diameter of about 3 mm. In other examples, other shapes and sizes of capsule can be used. For example, the capsule may have a diameter less than 4 mm, or less than 3.5 mm, or less than 3.25 mm. In alternative embodiments, the or each capsule may have a diameter greater than about 3.25 mm, for example greater than 3.5 mm, or greater than 4 mm. The total weight of each capsule may be in the range about 10 mg to about 50 mg.
In some embodiments, a single capsule is located at a longitudinally central position within the body of material 6. That is, the capsule 11 positioned so that its centre is 5 mm from each end of the body of material 6. In the present example, the centre of the capsule is positioned 36 mm from the upstream end of the article 1. Preferably, the capsule is positioned between 28 mm and 38 mm from the upstream end of the article 1, more preferably between 34 mm and 38 mm from the upstream end of the article 1. In the present example, the capsule is positioned 12 mm from the downstream end of the mouthpiece 2b. Providing a capsule at this position results in improved volatilisation of the capsule contents, due to the proximity of the capsule to the aerosol-generating section of the article which is heated in use, whilst also being far enough from the aerosol-generating section which, in use, is inserted into an aerosol provision system, to enable the user to readily access the capsule and burst it with their fingers.
In other examples, a single capsule is provided and is located at a position other than a longitudinally central position in the body of material 6, i.e. closer to the downstream end of the body of material 6 than the upstream end, or closer to the upstream end of the body of material 6 than the downstream end. Preferably, the mouthpiece 2, 2′ is configured so that the capsule and the ventilation holes are longitudinally offset from each other in the mouthpiece 2, 2′. For example, the ventilation holes may be provided immediately upstream of the capsule position, i.e. between about 1 mm and about 10 mm upstream of the capsule position.
In some embodiments, the aerosol modifying component comprises first and second capsules. The first capsule is disposed in a first portion of the aerosol modifying component and the second capsule is disposed in a second portion of the aerosol modifying component downstream of the first portion.
The first portion of the aerosol modifying component is heated to a first temperature during operation of the heater to generate the aerosol and the second portion is heated to a second temperature during operation of the heater to generate aerosol, wherein the second temperature is at least 4 degrees Celsius lower than the first temperature. Preferably, the second temperature is at least 5, 6, 7, 8, 9 or 10 degrees Celsius lower than the first temperature.
The aerosol modifying component may comprise one or more components of the article 1. In some embodiments, the aerosol modifying component comprises the body of material 6, wherein the first and second capsules are disposed in the body of material 6. The body of material 6 may comprise cellulose acetate. In another embodiment, the aerosol modifying component comprises two bodies of material (not shown), wherein the first and second capsules are disposed in the first and second bodies respectively. In some embodiments, the aerosol modifying component alternatively or additionally comprises one or more tubular elements upstream and/or downstream of the body or bodies of material. The aerosol generating component may comprise the mouthpiece 2, 2′.
In some embodiments, the second capsule is spaced from the first capsule by a distance of at least 7 mm, measured as the distance between the centre of the first and second capsules. Preferably, the second capsule is spaced from the first capsule by a distance of at least 8, 9 or 10 mm. It has been found that increasing the distance between the first and second capsules increases the difference between the first and second temperatures.
The first capsule comprises an aerosol modifying agent. The second capsule comprises an aerosol modifying agent which may be the same or different as the aerosol modifying agent of the first capsule. In some embodiments, a user may selectively rupture the first and second capsules by applying an external force to the aerosol modifying component in order to release the aerosol modifying agent from each capsule.
The aerosol-modifying agent of the second capsule is heated to a lower temperature than the aerosol-modifying agent of the first capsule due to the difference between the first and second temperatures.
The aerosol-modifying agents of the first and second capsules can be selected based on this temperature difference. For instance, the first capsule may comprise a first aerosol modifying agent that has a lower vapour pressure than a second aerosol modifying agent of the second capsule. If the capsules were both heated to the same temperature, then the higher vapour pressure of the aerosol modifying agent of the second capsule would mean that a greater amount of the second aerosol modifying agent would be volatised relative to the aerosol modifying agent of the first capsule. However, since the second capsule is heated to a lower temperature, this effect is less pronounced such that a more even amount of the aerosol modifying agents of the first and second capsules are volatised upon breaking of the first and second capsules respectively.
In some embodiments, the first and second capsules have the same aerosol-modifying profiles, meaning that both capsules contain the same type of aerosol-modifying agent and in the same amount such that if both capsules were heated to the same temperature and broken then both capsules would cause the same modification of the aerosol. However, since the first capsule is heated to a higher temperature than the second capsule, more of the aerosol-modifying agent of the first capsule will be, for example, volatised compared to the modifying agent of the second capsule and thus will cause a more pronounced modification of the aerosol than the second capsule. Therefore, despite both capsules being the same, which may make the aerosol modifying component easier and/or less expensive to manufacture, the user can decide whether to break the first capsule to cause a more pronounced modification of the aerosol, or the second capsule to cause a less pronounced modification of the aerosol, or both capsules to cause the greatest modification of the aerosol.
In some embodiments, the first and second capsules both comprise first and second aerosol modifying agents. The first aerosol modifying agent has a lower vapour pressure than the second aerosol modifying agent. Thus, when the second capsule is broken, a greater proportion of the second aerosol modifying agent will be vaporised relative to the first aerosol modifying agent in comparison to when the hotter first capsule is broken during use of the system to generate aerosol. Therefore, the same capsule can be used to generate different modifications of the aerosol based on the positon of the capsule in the first or second portion of the aerosol modifying component.
A non-combustible aerosol provision device is used to heat the aerosol generating material 3 of the articles 1, 1′ described herein. The non-combustible aerosol provision device preferably comprises a coil, since this has been found to enable improved heat transfer to the article 1, 1′ as compared to other arrangements.
In some examples, the coil is configured to, in use, cause heating of at least one electrically-conductive heating element, so that heat energy is conductible from the at least one electrically-conductive heating element to the aerosol generating material to thereby cause heating of the aerosol generating material.
In some examples, the coil is configured to generate, in use, a varying magnetic field for penetrating at least one heating element, to thereby cause induction heating and/or magnetic hysteresis heating of the at least one heating element. In such an arrangement, the or each heating element may be termed a “susceptor” as defined herein. A coil that is configured to generate, in use, a varying magnetic field for penetrating at least one electrically-conductive heating element, to thereby cause induction heating of the at least one electrically-conductive heating element, may be termed an “induction coil” or “inductor coil”.
The device may include the heating element(s), for example electrically-conductive heating element(s), and the heating element(s) may be suitably located or locatable relative to the coil to enable such heating of the heating element(s). The heating element(s) may be in a fixed position relative to the coil. Alternatively, the at least one heating element, for example at least one electrically-conductive heating element, may be included in the article 1, 1′ for insertion into a heating zone of the device, wherein the article 1, 1′ also comprises the aerosol generating material 3 and is removable from the heating zone after use. Alternatively, both the device and such an article 1, 1′ may comprise at least one respective heating element, for example at least one electrically-conductive heating element, and the coil may be to cause heating of the heating element(s) of each of the device and the article when the article is in the heating zone.
In some examples, the coil is helical. In some examples, the coil encircles at least a part of a heating zone of the device that is configured to receive aerosol generating material. In some examples, the coil is a helical coil that encircles at least a part of the heating zone.
In some examples, the device comprises an electrically-conductive heating element that at least partially surrounds the heating zone, and the coil is a helical coil that encircles at least a part of the electrically-conductive heating element. In some examples, the electrically-conductive heating element is tubular. In some examples, the coil is an inductor coil.
In some examples, the use of a coil enables the non-combustible aerosol provision device to reach operational temperature more quickly than a non-coil aerosol provision device. For instance, the non-combustible aerosol provision device including a coil as described above can reach an operational temperature such that a first puff can be provided in less than 30 seconds from initiation of a device heating program, more preferably in less than 25 seconds. In some examples, the device can reach an operational temperature in about 20 seconds from the initiation of a device heating program.
The use of a coil as described herein in the device to cause heating of the aerosol generating material has been found to enhance the aerosol which is produced. For instance, consumers have reported that the aerosol generated by a device including a coil such as that described herein is sensorially closer to that generated in factory made cigarette (FMC) products than the aerosol produced by other non-combustible aerosol provision systems. Without wishing to be bound by theory, it is hypothesised that this is the result of the reduced time to reach the required heating temperature when the coil is used, the higher heating temperatures achievable when the coil is used and/or the fact that the coil enables such systems to simultaneously heat a relatively large volume of aerosol generating material, resulting in aerosol temperatures resembling FMC aerosol temperatures. In FMC products, the burning coal generates a hot aerosol which heats tobacco in the tobacco rod behind the coal, as the aerosol is drawn through the rod. This hot aerosol is understood to release flavour compounds from tobacco in the rod behind the burning coal. A device including a coil as described herein is thought to also be capable of heating aerosol generating material, such as tobacco material described herein, to release flavour compounds, resulting in an aerosol which has been reported to more closely resemble an FMC aerosol. Particular improvements in aerosol can be achieved through the use of a device including a coil to heat an article comprising a rod of aerosol generating material having a circumference greater than 19 mm, for instance a circumference between about 19 mm and about 23 mm.
Using an aerosol provision system including a coil as described herein, for instance an induction coil which heats at least some of the aerosol generating material to at least 200° C., more preferably at least 220° C., can enable the generation of an aerosol from an aerosol generating material that has particular characteristics which are thought to more closely resemble those of an FMC product. For example, when heating an aerosol generating material, including nicotine, using an induction heater, heated to at least 250° C., for a two-second period, under an airflow of at least 1.50 L/m during the period, one or more of the following characteristics has been observed:
In some cases, at least 10 μg of nicotine, suitably at least 30 μg or 40 μg of nicotine, is aerosolised from the aerosol generating material under an airflow of at least 1.50 L/m during the period. In some cases, less than about 200 μg, suitably less than about 150 μg or less than about 125 μg, of nicotine is aerosolised from the aerosol generating material under an airflow of at least 1.50 L/m during the period.
In some cases, the aerosol contains at least 100 μg of the aerosol-former material, suitably at least 200 μg, 500 μg or 1 mg of aerosol-former material is aerosolised from the aerosol generating material under an airflow of at least 1.50 L/m during the period. Suitably, the aerosol-former material may comprise or consist of glycerol.
As defined herein, the term “mean particle or droplet size” refers to the mean size of the solid or liquid components of an aerosol (i.e. the components suspended in a gas). Where the aerosol contains suspended liquid droplets and suspended solid particles, the term refers to the mean size of all components together.
In some cases, the mean particle or droplet size in the generated aerosol may be less than about 900 nm, 800 nm, 700, nm 600 nm, 500 nm, 450 nm or 400 nm. In some cases, the mean particle or droplet size may be more than about 25 nm, 50 nm or 100 nm.
In some cases, the aerosol density generated during the period is at least 0.1 μg/cc. In some cases, the aerosol density is at least 0.2 μg/cc, 0.3 μg/cc or 0.4 μg/cc. In some cases, the aerosol density is less than about 2.5 μg/cc, 2.0 μg/cc, 1.5 μg/cc or 1.0 μg/cc.
The non-combustible aerosol provision device is preferably arranged to heat the aerosol generating material 3 of the article 1, 1′, to a maximum temperature of at least 160° C. Preferably, the non-combustible aerosol provision device is arranged to heat the aerosol-former material 3 of the article 1, 1′, to a maximum temperature of at least about 200° C., or at least about 220° C., or at least about 240° C., more preferably at least about 270° C., at least once during the heating process followed by the non-combustible aerosol provision device.
Using an aerosol provision system including a coil as described herein, for instance an induction coil which heats at least some of the aerosol generating material to at least 200° C., more preferably at least 220° ° C., can enable the generation of an aerosol from an aerosol generating material in an article 1, 1′ as described herein that has a higher temperature as the aerosol leaves the mouth end of the mouthpiece 2, 2′ than previous devices, contributing to the generation of an aerosol which is considered closer to an FMC product. For instance, the maximum aerosol temperature measured at the mouth-end of the article 1, 1′ can preferably be greater than 50° C., more preferably greater than 55° C. and still more preferably greater than 56° C. or 57° C. Additionally or alternatively, the maximum aerosol temperature measured at the mouth-end of the article 1, 1″ can be less than 62° C., more preferably less than 60° C. and more preferably less than 59° C. In some embodiments, the maximum aerosol temperature measured at the mouth-end of the article 1, 1′ can preferably be between 50° C. and 62° C., more preferably between 56° C. and 60° C.
In the above described embodiments the tubular portion 4a is provided in a mouthpiece 2, 2′. However, it should be recognised that in alternative embodiments the tubular portion 4a may be provided in a different component of the article 1, 1′ upstream of the mouthpiece 2, 2′, but still in a portion of the article that is downstream of the aerosol generating material 3.
In some embodiments, the aerosol-generating material 3 comprises a sheet or a shredded sheet of aerosolisable material. The aerosolisable material is arranged to generate aerosol when heated.
The sheet or shredded sheet comprises a first surface and a second surface opposite the first surface. The dimensions of the first and second surfaces are roughly congruent. The first and second surfaces of the sheet or shredded sheet may have any shape. For example, the first and second surfaces may be square, rectangular, oblong or circular. Irregular shapes are also envisaged.
The first and/or second surfaces of the sheet or shredded sheet may be relatively uniform (e.g. they may be relatively smooth) or they may uneven or irregular. For example, the first and/or second surfaces of the sheet may be textured or patterned to define a relatively coarse surface. In some embodiments, the first and/or second surfaces are relatively rough.
The smoothness of the first and second surfaces may be influenced by a number of factors, such as their area density and the nature of the components that make up the aerosolisable material.
The area of the first and second surfaces are each defined by a first dimension (e.g. a width) and a second dimension (e.g. a length). As used herein, the term “aspect ratio” is the ratio of a measurement of the first dimension of the first or second surface to a measurement of the second dimension of the first or second surface. The measurements of the first and second dimensions may have a ratio of 1:1 or greater than 1:1 and thus the sheet or shredded sheet may have an “aspect ratio” of 1:1 or greater than 1:1. An “aspect ratio of 1:1” means that a measurement of the first dimension (e.g. width) and a measurement of the second dimension (e.g. length) are identical. An “aspect ratio of greater than 1:1” a measurement of the first dimension (e.g. width) and a measurement of the second dimension (e.g. length) are different. In some embodiments, the first and second surfaces of the sheet or shredded sheet have an aspect ratio of greater than 1:1, such as 1:2, 1:3, 1:4, 1:5, 1:6, 1:7 or more.
The shredded sheet may comprise one or more strands or strips of the aerosolisable material. In some embodiments, the shredded sheet comprises a plurality (e.g. two or more) strands or strips of the aerosolisable material. The strands or strips of aerosolisable material have an aspect ratio of at least 1:1. In an embodiment, the strands or strips of aerosolisable material have an aspect ratio of greater than 1:1. In some embodiments, the strands or strips of aerosolisable material have an aspect ratio of from about 1:5 to about 1:16, or about 1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:11 or 1:12.
Where the shredded sheet comprises a plurality of strands or strips of material, the dimensions of each strand or strip may by identical, similar or different. For example, the shredded sheet may comprise a first population of strands or strips and a second population of strands or strips, wherein the dimensions of the strands or strips of the first population are different to the dimensions of the strands or strips of the second population. For example, the plurality of strands or strips may comprise a first population of strands or strips having a first aspect ratio and a second population of strands or strips having a second aspect ratio that is different to the first aspect ratio.
Preferably a first dimension, or cut width, of the strands or strips of aerosolisable material is between 0.75 mm and 2 mm, for instance between 1 mm and 1.5 mm. It is thought that when strands or strips of aerosolisable material having a cut width of below 0.75 mm are incorporated into an article for use in a non-combustible aerosol provision system, the pressure drop across the article may be increased. Conversely, if the strands or strips have a cut width above 2 mm (e.g. greater than 2 mm), then it may be challenging to insert the strands or strips of aerosolisable material into the article during its manufacture.
The strands or strips of material formed by shredding may be cut width-wise, for example in a cross-cut type shredding process, to define a cut length for the strands or strips of aerosolisable material, in addition to a cut width. The cut length of the shredded aerosolisable material is preferably at least 5 mm, for instance at least 10 mm, or at least 20 mm. The cut length of the shredded aerosolisable material can be less than 60 mm, less than 50 mm, or less than 40 mm.
In some embodiments, a plurality of strands or strips of aerosolisable material is provided and at least one of the plurality of strands or strips of aerosolisable material has a length greater than about 10 mm. At least one of the plurality of strands or strips of aerosolisable material can alternatively or in addition have a length between about 10 mm and about 60 mm, or between about 20 mm and about 50 mm. Each of the plurality of strands or strips of aerosolisable material can have a length between about 10 mm and about 60 mm, or between about 20 mm and about 50 mm.
The sheet or shredded sheet may be a relatively thin material. The thickness of the sheet or shredded sheet may vary between the first and second surfaces. The sheet or shredded sheet of aerosolisable material has a thickness of at least about 100 μm. The sheet or the shredded sheet may have a thickness of at least about 120 μm, 140 μm, 160 μm, 180 μm or 200 μm. In some embodiments, the sheet or shredded sheet has a thickness of from about 150 μm to about 300 μm, from about 151 μm to about 299 μm, from about 152 μm to about 298 μm, from about 153 μm to about 297 μm, from about 154 μm to about 296 μm, from about 155 μm to about 295 μm, from about 156 μm to about 294 μm, from about 157 μm to about 293 μm, from about 158 μm to about 292 μm, from about 159 μm to about 291 μm or from about 160 μm to about 290 μm. In some embodiments, the sheet or shredded sheet has a thickness of from about 170 μm to about 280 μm, from about 180 to about 270 μm, from about 190 to about 260 μm, from about 200 μm to about 250 μm or from about 210 μm to about 240 μm.
In some embodiments, an individual strip or piece of the aerosolisable material has a minimum thickness over its area of about 100 μm. In some cases, an individual strip or piece of the aerosol-generating material has a minimum thickness over its area of about 0.05 mm or about 0.1 mm. In some cases, an individual strip or piece of the aerosol-generating material has a maximum thickness over its area of about 1.0 mm. In some cases, an individual strip or piece of the aerosol-generating material has a maximum thickness over its area of about 0.5 mm or about 0.3 mm.
The thickness of the sheet can be determined using the Guobiao standards method outlined in “GB/T 451.3 Paper and board-Determination of thickness”.
The inventors have established that if the sheet or shredded sheet of aerosolisable material is too thick, then heating efficiency can be compromised. This can adversely affect power consumption in use, for instance the power consumption for release of flavour from the aerosolisable material. Conversely, if the aerosolisable material is too thin, it can be difficult to manufacture and handle; a very thin material can be harder to cast and may be fragile, compromising aerosol formation in use.
It has been observed that a sheet or shredded sheet having a thickness of at least about 100 μm, along with an area density of from about 100 g/m2 to about 250 g/m2 is less liable to tear, split or become otherwise deformed during its manufacture. A thickness of at least about 100 μm may have a positive effect on the overall structural integrity and strength of sheet or shredded sheet. For example, it may have a good tensile strength and thus be relatively easy to process the material.
The thickness of the sheet or shredded sheet is also thought to have a bearing on its area density. That is to say, increasing the thickness of the sheet or shredded sheet may decrease the area density of the sheet or shredded sheet. Conversely, decreasing the thickness of the sheet or shredded sheet may increase the area density of the sheet or shredded sheet. For the avoidance of doubt, where reference is made herein to area density, this refers to an average area density calculated for a given strip, strand, piece or sheet of the aerosolisable material, the area density calculated by measuring the surface area and weight of the given strip, strand, piece or sheet of aerosolisable material.
The sheet or shredded sheet of aerosol-generating material has an area density of from about 100 g/m2 to about 250 g/m2. The sheet or shredded sheet may have an area density of from about 110 g/m2 to about 240 g/m2, from about 120 g/m2 to about 230 g/m2, from about 130 g/m2 to about 220 g/m2 or from about 140 g/m2 to about 210 g/m2. In some embodiments, the sheet or shredded sheet has an area density of from about 130 g/m2 to about 290 g/m2, from about 140 g/m2 to about 180 g/m2, from about 150 g/m2 to about 170 g/m2.
The area density of about 100 g/m2 to about 250 g/m2 is thought to contribute to the strength and flexibility of sheet or shredded sheet.
The flexibility of the sheet or shredded sheet is considered to be dependent upon the thickness and area density of the sheet or shredded sheet. A thicker sheet or shredded sheet may be less flexible than a thinner sheet or shredded sheet. Also, the greater the area density of the sheet, the less flexible the sheet or shredded sheet is. It is thought that the combined thickness and area density of the aerosolisable material described herein provides a sheet or shredded sheet that is relatively flexible. When the aerosolisable material is incorporated into an article for use in a non-combustible aerosol-provision device, this flexibility, may give rise to various advantages. For example, the strands or strips are able to readily deform and flex when an aerosol generator is inserted into the aerosol generating material, thus improving the ease by which the aerosol generator may be inserted into the material.
The inventors have found that the area density of the sheet or shredded sheet of aerosol-generating material influences the roughness of the first and second surfaces of the sheet or shredded sheet. By changing the area density, the roughness of the first and/or second surfaces can be tailored. Increasing the area density deceases the roughness of the first and second surfaces, whilst decreasing the area density increases the roughness of the first and second surfaces.
The average volume density of the sheet or shredded sheet of aerosol-generating material may be calculated from the thickness of the sheet and the area density of the sheet. The average volume density may be greater than about 0.2 g/cm3, about 0.3 g/cm3 or about 0.4 g/cm3. In some embodiments, the average volume density is from about 0.2 g/cm3 to about 1 g/cm3, from about 0.3 g/cm3 to about 0.9 g/cm3, from about 0.4 g/cm3 to about 0.8 g/cm3, from about 0.5 g/cm3 to about 0.8 g/cm3 or from about 0.6 g/cm3 to about 0.8 g/cm3.
According to an aspect of the disclosure, there is provided an aerosol-generating material comprising a sheet or shredded sheet of aerosolisable material comprising tobacco material, an aerosol-former material and a binder, wherein the sheet or shredded sheet has a density of greater than about 0.4 g/cm3. In some embodiments, the density is from about 0.4 g/cm3 to about 2.9 g/cm3, from about 0.4 g/cm3 to about 1 g/cm3, from about 0.6 cm3 to about 1.6 cm3 or from about 1.6 cm3 to about 2.9 cm3.
The sheet or shredded sheet may have a tensile strength of at least 4 N/15 mm. The inventors have found that, where the sheet or shredded sheet has a tensile strength below 4 N/15 mm, the sheet or shredded sheet is likely to tear, break or otherwise deform during its manufacture and/or subsequent incorporation into an article for use in a non-combustible aerosol provision system.
The tobacco material may be a particulate or granular material. In some embodiments, the tobacco material is a powder. Alternatively or in addition, the tobacco material may comprise may comprise strips, strands or fibres of tobacco. For example, the tobacco material may comprise particles, granules, fibres, strips and/or strands of tobacco. In some embodiments, the tobacco material consists of particles or granules of tobacco material.
The density of the tobacco material has an impact on the speed at which heat conducts through the material, with lower densities, for instance those below 700 mg/cc, conducting heat more slowly through the material, and therefore enabling a more sustained release of aerosol.
The tobacco material can comprise reconstituted tobacco material having a density of less than about 700 mg/cc, for instance paper reconstituted tobacco material. For instance, the aerosol-generating material 3 comprises reconstituted tobacco material having a density of less than about 600 mg/cc. Alternatively or in addition, the aerosol-generating material 3 can comprise reconstituted tobacco material having a density of at least 350 mg/cc.
The tobacco material may be provided in the form of cut rag tobacco. The cut rag tobacco can have a cut width of at least 15 cuts per inch (about 5.9 cuts per cm, equivalent to a cut width of about 1.7 mm). Preferably, the cut rag tobacco has a cut width of at least 18 cuts per inch (about 7.1 cuts per cm, equivalent to a cut width of about 1.4 mm), more preferably at least 20 cuts per inch (about 7.9 cuts per cm, equivalent to a cut width of about 1.27 mm). In one example, the cut rag tobacco has a cut width of 22 cuts per inch (about 8.7 cuts per cm, equivalent to a cut width of about 1.15 mm). Preferably, the cut rag tobacco has a cut width at or below 40 cuts per inch (about 15.7 cuts per cm, equivalent to a cut width of about 0.64 mm). Cut widths between 0.5 mm and 2.0 mm, for instance between 0.6 and 1.7 mm or between 0.6 mm and 1.5 mm, have been found to result in tobacco material which is preferably in terms of surface area to volume ratio, particularly when heated, and the overall density and pressure drop of the rod of aerosol-generating material 3. The cut rag tobacco can be formed from a mixture of forms of tobacco material, for instance a mixture of one or more of paper reconstituted tobacco, leaf tobacco, extruded tobacco and bandcast tobacco. Preferably the tobacco material comprises paper reconstituted tobacco or a mixture of paper reconstituted tobacco and leaf tobacco.
The tobacco material may have any suitable thickness. The tobacco material may have a thickness of at least about 0.145 mm, for instance at least about 0.15 mm, or at least about 0.16 mm. The tobacco material may have a maximum thickness of about 0.25 mm, for instance the thickness of the tobacco material may be less than about 0.22 mm, or less than about 0.2 mm. In some embodiments, the tobacco material may have an average thickness in the range 0.175 mm to 0.195 mm. Such thicknesses may be particularly suitable where the tobacco material is a reconstituted tobacco material.
In some embodiments, the tobacco is a particulate tobacco material. Each particle of the particulate tobacco material may have a maximum dimension. As used herein, the term “maximum dimension” refers to the longest straight line distance from any point on the surface of a particle of tobacco, or on a particle surface, to any other surface point on the same particle of tobacco, or particle surface. The maximum dimension of a particle of particulate tobacco material may be measured using scanning electron microscopy (SEM).
The maximum dimension of each particle of tobacco material can be up to about 200 μm. In some embodiments, the maximum dimension of each particle of tobacco material is up to about 150 μm.
A population of particles of the tobacco material may have a particle size distribution (D90) of at least about 100 μm. In some embodiments, a population of particles of the tobacco material has a particle size distribution (D90) of about 110 μm, at least about 120 μm, at least about 130 μm, at least about 140 μm or at least about μm. In an embodiment, a population of particles of the tobacco material has a particle size distribution (D90) of about 150 μm. Sieve analysis can also be used to determine the particle size distribution of the particles of tobacco material.
A particle size distribution (D90) of at least about 100 μm is thought to contribute to the tensile strength of the sheet or shredded sheet of aerosolisable material.
The inventors have found that a particle size distribution (D90) of less than 100 μm provides a sheet or shredded sheet of aerosolisable material having good tensile strength. However, the inclusion of such fine particles of tobacco material in the sheet or shredded sheet can increase its density. When the sheet or shredded sheet is incorporated into an article for use in a non-combustible aerosol provision system, this higher density may decrease the fill-value of the tobacco material. Advantageously, the inventors have found that a balance between a satisfactory tensile strength and suitable density may be achieved where the particle size distribution (D90) is at least about 100 μm.
The particle size of the particulate tobacco material can also influence the roughness of the sheet or shredded sheet of aerosol generating material. Forming the sheet or shredded sheet of aerosol-generating material by incorporating relatively large particles of tobacco material decreases the density of the sheet or shredded sheet of aerosol generating material.
The tobacco material may comprise tobacco obtained from any part of the tobacco plant. In some embodiments, the tobacco material comprises tobacco leaf.
The sheet or shredded sheet can comprise from 5% to about 90% by weight tobacco leaf.
The tobacco material may comprise lamina tobacco and/or tobacco stem, such as midrib stem. The lamina tobacco can be present in an amount of from 0% to about 100%, from about 20% to about 100%, from about 40% to about 100%, from about 40% to about 95%, from about 45% to about 90%, from about 50% to about 85% or from about 55% to about 80% by weight of the sheet or shredded sheet. In some embodiments, tobacco material consists or consists essentially of lamina tobacco material.
The tobacco material may comprise tobacco stem in an amount of from 0% to about 100%, from about 0% to about 50%, from about 0 to about 25%, from about 0 to about 20%, from about 5 to about 15% by weight of the sheet or shredded sheet. The inventors have found that the incorporation of stem may decrease the tackiness of the aerosolisable material.
In some embodiments, the tobacco material comprises a combination of lamina and tobacco stem. In some embodiments, the tobacco material can comprise lamina in an amount of from about 40% to about 95% and stem in an amount of from about 5% to about 60%, or lamina in an amount of from about 60% to about 95% and stem in an amount of from about 5% to about 40%, or lamina in an amount of from about 80% to about 95% and stem in an amount of from about 5% to about 20% by weight of the sheet or shredded sheet of aerosolisable material.
The sheet or the shredded sheet of aerosolisable material may have a burst strength of at least about 75 g, at least about 100 g or at least about 200 g.
If the burst strength is too low the sheet or shredded sheet may be relatively brittle. As a result, breakages in the sheet or shredded sheet may occur during the process of manufacturing the aerosolisable material. For example, when the sheet is shredded to form a shredded sheet by a cutting process, the sheet may shatter or break into pieces or shards when cut.
The inventors have surprisingly found that incorporating tobacco material comprising stem tobacco into the aerosolisable material increases its burst strength.
The tobacco material described herein contains nicotine. The nicotine content is from 0.1 to 3% by weight of the tobacco material, and may be, for example, from 0.5 to 2.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material contains between 10% and 90% by weight tobacco leaf having a nicotine content of greater than 1.5% by weight of the tobacco leaf. It has been advantageously found that using a tobacco leaf with nicotine content higher than 1.5% in combination with a lower nicotine base material, such as paper reconstituted tobacco, provides a tobacco material with an appropriate nicotine level but better sensory performance than the use of paper reconstituted tobacco alone. The tobacco leaf, for instance cut rag tobacco, can, for instance, have a nicotine content of between 1.5% and 5% by weight of the tobacco leaf.
Paper reconstituted tobacco may be present in the aerosol-generating material described herein. Paper reconstituted tobacco refers to tobacco material formed by a process in which tobacco feedstock is extracted with a solvent to afford an extract of solubles and a residue comprising fibrous material, and then the extract (usually after concentration, and optionally after further processing) is recombined with fibrous material from the residue (usually after refining of the fibrous material, and optionally with the addition of a portion of non-tobacco fibres) by deposition of the extract onto the fibrous material. The process of recombination resembles the process for making paper.
The paper reconstituted tobacco may be any type of paper reconstituted tobacco that is known in the art. In a particular embodiment, the paper reconstituted tobacco is made from a feedstock comprising one or more of tobacco strips, tobacco stems, and whole leaf tobacco. In a further embodiment, the paper reconstituted tobacco is made from a feedstock consisting of tobacco strips and/or whole leaf tobacco, and tobacco stems. However, in other embodiments, scraps, fines and winnowings can alternatively or additionally be employed in the feedstock.
The paper reconstituted tobacco for use in the tobacco material described herein may be prepared by methods which are known to those skilled in the art for preparing paper reconstituted tobacco.
In embodiments, the paper reconstituted tobacco is present in an amount of from 5% to 90% by weight, 10% to 80% by weight, or 20% to 70% by weight, of the aerosol-generating material.
An aerosol-former material comprises one or more constituents capable of forming an aerosol. The aerosol-former material comprises one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
The sheet or shredded sheet of aerosolisable material comprises an aerosol-former material. The aerosol-former material is provided in an amount of up to about 50% on a dry weight base by weight of the sheet or shredded sheet. In some embodiments, the aerosol former material is provided in an amount of from about 5% to about 40% on a dry weight base by weight of the sheet or shredded sheet, from about 10% to about 30% on a dry weight base by weight of the sheet or shredded sheet or from about 10% to about 20% on a dry weight base by weight of the sheet or shredded sheet.
The sheet or shredded sheet may also comprise water. The sheet or shredded sheet of aerosolisable material may comprise water in an amount of less than about 15%, less than about 10% or less than about 5% by weight of the aerosolisable material. In some embodiments, the aerosolisable material comprises water in an amount of between about 0% and about 15% or between about 5% and about 15% by weight of the aerosolisable material.
The sheet or shredded sheet of aerosolisable material may comprise water and glycerol, in a total amount, of less than about 30% by weight of the sheet or shredded sheet of aerosolisable material or less than about 25% by weight of the sheet or shredded sheet of aerosolisable material. It is thought that incorporating less water and glycerol in the sheet or shredded sheet of aerosolisable material in an amount of less than about 30% by weight of the sheet or shredded sheet of aerosolisable may advantageously reduce the tackiness of the sheet. This may improve the ease by which the aeroslisable material can be handled, particulately during processing. For example, it may be easier to roll a sheet of aerosolisable material to form a bobbin of material. Reducing the tackiness may also decrease the propensity for the strands or strips of shredded material to clump or stick together, thus further improving processing efficiency and the quality of the final product.
The sheet or shredded sheet comprises a binder. The binder is arranged to bind the components of the aerosol-generating material to form the sheet or shredded sheet. The binder may at least partially coat the surface of the tobacco material. Where the tobacco material is in a particulate form, the binder may at least partially coat the surface of the particles of tobacco and bind them together.
The aerosol-generating material may comprise a filler. In some embodiments, the sheet or shredded sheet comprises the filler. The filler is generally a non-tobacco component, that is, a component that does not include ingredients originating from tobacco. The filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may be a non-tobacco fibre such as wood fibre or pulp or wheat fibre. The filler can be a material comprising cellulose or a material comprises a derivate of cellulose. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material.
In particular embodiments which include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood, wood pulp, hemp fibre, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that including fibrous filler in an amorphous solid may increase the tensile strength of the material.
The filler may also contribute to the texture of the sheet or shredded sheet of the aerosol generating material. For example, a fibrous filler, such as wood or wood pulp, may provide a sheet or shredded sheet of aerosol generating material having relatively rough first and second surfaces. Conversely, a non-fibrous, particulate filler, such as powdered chalk, may provide a sheet or shredded sheet of aerosol generating material having relatively smooth first and second surfaces. In some embodiments, the aerosol-generating material comprises a combination of different filler materials.
The filler component may be present in an amount of 0 to 20% by weight of the sheet or shredded sheet, or in an amount of from 1 to 10% by weight of the composition. In some embodiments, the filler component is absent.
The filler may help to improve the general structural properties of the aeroslisable material, such as its tensile strength and burst strength.
In the compositions described herein, where amounts are given in % by weight, for the avoidance of doubt this refers to a dry weight basis, unless specifically indicated to the contrary. Thus, any water that may be present in the tobacco material, or in any component thereof, is entirely disregarded for the purposes of the determination of the weight %. The water content of the tobacco material described herein may vary and may be, for example, from 5 to 15% by weight. The water content of the tobacco material described herein may vary according to, for example, the temperature, pressure and humidity conditions at which the compositions are maintained. The water content can be determined by Karl-Fisher analysis, as known to those skilled in the art.
The aerosol-generating material herein can comprise an aerosol modifying agent, such as any of the flavours described herein. In one embodiment, the aerosol-generating material comprises menthol. When the aerosol-generating material is incorporated into an article for use in an aerosol-provision system, the article may be referred to as a mentholated article. The aerosol-generating material can comprise from 3 mg to 20 mg of menthol, preferably between 5 mg and 18 mg and more preferably between 8 mg and 16 mg of menthol. In the present example, the aerosol-generating material comprises 16 mg of menthol. The aerosol-generating material can comprise between 2% and 8% by weight of menthol, preferably between 3% and 7% by weight of menthol and more preferably between 4% and 5.5% by weight of menthol. In one embodiment, the aerosol-generating material comprises 4.7% by weight of menthol. Such high levels of menthol loading can be achieved using a high percentage of reconstituted tobacco material, for instance greater than 50% of the tobacco material by weight. Alternatively or additionally, the use of a high volume of, for instance tobacco material, can increase the level of menthol loading that can be achieved, for instance where greater than about 500 mm3 or suitably more than about 1000 mm3 of aerosol-generating material, such as tobacco material, are used.
In some embodiments, the composition comprises an aerosol-forming “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some embodiments, the amorphous solid may comprise a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it.
In some examples, the amorphous solid comprises:
In some further embodiments, the amorphous solid comprises:
The amorphous solid material may be provided in sheet form.
Suitably, the amorphous solid may comprise from about 1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 60 wt %, 50 wt %, 45 wt %, 40 wt % or 35 wt % of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-50 wt %, 5-45 wt %, 10-40 wt % or 20-35 wt % of a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the gelling agent comprises alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during formation of the amorphous solid. In some cases, the amorphous solid may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.
In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of from 10-30 wt % of the amorphous solid (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one further gelling agent, such as pectin.
In some embodiments the amorphous solid may include gelling agent comprising carrageenan.
Suitably, the amorphous solid may comprise from about 0.1 wt %, 0.5 wt %, 1 wt %, 3 wt %, 5 wt %, 7 wt % or 10% to about 50 wt %, 45 wt %, 40 wt %, 35 wt %, 30 wt % or 25 wt % of an aerosol-former material (all calculated on a dry weight basis). The aerosol-former material may act as a plasticiser. For example, the amorphous solid may comprise 0.5-40 wt %, 3-35 wt % or 10-25 wt % of an aerosol-former material. In some cases, the aerosol-former material comprises one or more compound selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases, the aerosol-former material comprises, consists essentially of or consists of glycerol.
The amorphous solid comprises a flavour. Suitably, the amorphous solid may comprise up to about 80 wt %, 70 wt %, 60 wt %, 55 wt %, 50 wt % or 45 wt % of a flavour.
In some cases, the amorphous solid may comprise at least about 0.1 wt %, 1 wt %, 10 wt %, 20 wt %, 30 wt %, 35 wt % or 40 wt % of a flavour (all calculated on a dry weight basis).
For example, the amorphous solid may comprise 1-80 wt %, 10-80 wt %, 20-70 wt %, 30-60 wt %, 35-55 wt % or 30-45 wt % of a flavour. In some cases, the flavour comprises, consists essentially of or consists of menthol.
In some cases, the amorphous solid may additionally comprise an emulsifying agent, which emulsified molten flavour during manufacture. For example, the amorphous solid may comprise from about 5 wt % to about 15 wt % of an emulsifying agent (calculated on a dry weight basis), suitably about 10 wt %. The emulsifying agent may comprise acacia gum.
In some embodiments, the amorphous solid is a hydrogel and comprises less than about 20 wt % of water calculated on a wet weight basis. In some cases, the hydrogel may comprise less than about 15 wt %, 12 wt % or 10 wt % of water calculated on a wet weight basis. In some cases, the hydrogel may comprise at least about 1 wt %, 2 wt % or at least about 5 wt % of water (WWB).
In some embodiments, the amorphous solid additionally comprises an active substance. For example, in some cases, the amorphous solid additionally comprises a tobacco material and/or nicotine. In some cases, the amorphous solid may comprise 5-60 wt % (calculated on a dry weight basis) of a tobacco material and/or nicotine. In some cases, the amorphous solid may comprise from about 1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 70 wt %, 60 wt %, 50 wt %, 45 wt %, 40 wt %, 35 wt %, or 30 wt % (calculated on a dry weight basis) of an active substance. In some cases, the amorphous solid may comprise from about 1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 70 wt %, 60 wt %, 50 wt %, 45 wt %, 40 wt %, 35 wt %, or 30 wt % (calculated on a dry weight basis) of a tobacco material. For example, the amorphous solid may comprise 10-50 wt %, 15-40 wt % or 20-35 wt % of a tobacco material. In some cases, the amorphous solid may comprise from about 1 wt %, 2 wt %, 3 wt % or 4 wt % to about 20 wt %, 18 wt %, 15 wt % or 12 wt % (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may comprise 1-20 wt %, 2-18 wt % or 3-12 wt % of nicotine.
In some cases, the amorphous solid comprises an active substance such as tobacco extract. In some cases, the amorphous solid may comprise 5-60 wt % (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid may comprise from about 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 60 wt %, 50 wt %, 45 wt %, 40 wt %, 35 wt %, or 30 wt % (calculated on a dry weight basis) tobacco extract. For example, the amorphous solid may comprise 10-50 wt %, 15-40 wt % or 20-35 wt % of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the amorphous solid comprises 1 wt % 1.5 wt %, 2 wt % or 2.5 wt % to about 6 wt %, 5 wt %, 4.5 wt % or 4 wt % (calculated on a dry weight basis) of nicotine.
In some cases, there may be no nicotine in the amorphous solid other than that which results from the tobacco extract.
In some embodiments the amorphous solid comprises no tobacco material but does comprise nicotine. In some such cases, the amorphous solid may comprise from about 1 wt %, 2 wt %, 3 wt % or 4 wt % to about 20 wt %, 18 wt %, 15 wt % or 12 wt % (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may comprise 1-20 wt %, 2-18 wt % or 3-12 wt % of nicotine.
In some cases, the total content of active substance and/or flavour may be at least about 0.1 wt %, 1 wt %, 5 wt %, 10 wt %, 20 wt %, 25 wt % or 30 wt %. In some cases, the total content of active substance and/or flavour may be less than about 90 wt %, 80 wt %, 70 wt %, 60 wt %, 50 wt % or 40 wt % (all calculated on a dry weight basis).
In some cases, the total content of tobacco material, nicotine and flavour may be at least about 0.1 wt %, 1 wt %, 5 wt %, 10 wt %, 20 wt %, 25 wt % or 30 wt %. In some cases, the total content of active substance and/or flavour may be less than about 90 wt %, 80 wt %, 70 wt %, 60 wt %, 50 wt % or 40 wt % (all calculated on a dry weight basis).
The amorphous solid may be made from a gel, and this gel may additionally comprise a solvent, included at 0.1-50 wt %. However, the inventors have established that the inclusion of a solvent in which the flavour is soluble may reduce the gel stability and the flavour may crystallise out of the gel. As such, in some cases, the gel does not include a solvent in which the flavour is soluble.
In some embodiments, the amorphous solid comprises less than 60 wt % of a filler, such as from 1 wt % to 60 wt %, or 5 wt % to 50 wt %, or 5 wt % to 30 wt %, or 10 wt % to 20 wt %.
In other embodiments, the amorphous solid comprises less than 20 wt %, suitably less than 10 wt % or less than 5 wt % of a filler. In some cases, the amorphous solid comprises less than 1 wt % of a filler, and in some cases, comprises no filler.
The filler, if present, may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives. In particular cases, the amorphous solid comprises no calcium carbonate such as chalk.
In particular embodiments which include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that including fibrous filler in an amorphous solid may increase the tensile strength of the material.
In some embodiments, the amorphous solid does not comprise tobacco fibres.
In some examples, the amorphous solid in sheet form may have a tensile strength of from around 200 N/m to around 900 N/m. In some examples, such as where the amorphous solid does not comprise a filler, the amorphous solid may have a tensile strength of from 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the amorphous solid material is formed as a sheet and then shredded and incorporated into an aerosol-generating article.
In some examples, such as where the amorphous solid comprises a filler, the amorphous solid may have a tensile strength of from 600 N/m to 900 N/m, or from 700 N/m to 900 N/m, or around 800 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the amorphous solid material is included in an aerosol-generating article as a rolled sheet, suitably in the form of a tube.
In some cases, the amorphous solid may consist essentially of, or consist of a gelling agent, water, an aerosol-former material, a flavour, and optionally an active substance.
In some cases, the amorphous solid may consist essentially of, or consist of a gelling agent, water, an aerosol-former material, a flavour, and optionally a tobacco material and/or a nicotine source.
The amorphous solid may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.
The aerosol-generating material can comprise a paper reconstituted tobacco material. The composition can alternatively or additionally comprise any of the forms of tobacco described herein. The aerosol generating material can comprise a sheet or shredded sheet comprising tobacco material comprising between 10% and 90% by weight tobacco leaf, wherein an aerosol-former material is provided in an amount of up to about 20% by weight of the sheet or shredded sheet, and the remainder of the tobacco material comprises paper reconstituted tobacco.
Where the aerosol-generating material comprises an amorphous solid material, the amorphous solid material may be a dried gel comprising menthol. In alternative embodiments, the amorphous solid may have any composition as described herein.
The inventors have advantageously found that an improved article may be produced comprising aerosol-generating material comprising a first component comprising a sheet or shredded sheet of aerosolisable material and a second component comprising amorphous solid, wherein the material properties (e.g. density) and specification (e.g. thickness, length, and cut width) fall within the ranges set out herein.
In some cases, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. The inventors have found that a material having a thickness of about 0.09 mm can be used. The amorphous solid may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.
The thickness of the amorphous solid material may be measured using a calliper or a microscope such as a scanning electron microscope (SEM), as known to those skilled in the art, or any other suitable technique known to those skilled in the art.
The inventors have established that if the amorphous solid is too thick, then heating efficiency can be compromised. This can adversely affect power consumption in use, for instance the power consumption for release of flavour from the amorphous solid. Conversely, if the aerosol-forming amorphous solid is too thin, it can be difficult to manufacture and handle; a very thin material can be harder to cast and may be fragile, compromising aerosol formation in use. In some cases, an individual strip or piece of the amorphous solid has a minimum thickness over its area of about 0.015. In some cases, an individual strip or piece of the amorphous solid has a minimum thickness over its area of about 0.05 mm or about 0.1 mm. In some cases, an individual strip or piece of the amorphous solid has a maximum thickness over its area of about 1.0 mm.
In some cases, an individual strip or piece of the amorphous solid has a maximum thickness over its area of about 0.5 mm or about 0.3 mm.
In some cases, the amorphous solid thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1% across its area.
The inventors have found that providing amorphous solid material and sheet or shredded sheet of aerosolisable material having area density values that differ from each other by less than a given percentage results in less separation in a mixture of these materials. In some examples, the area density of the amorphous solid material may be between 50% and 150% of the area density of the aerosolisable material. For instance, the area density of the amorphous solid material may be between 60% and 140% of the density of the aerosolisable material, or between 70% and 110% of the area density of the aerosolisable material, or between 80% and 120% of the area density of the aerosolisable material.
In embodiments described herein, the amorphous solid material may be incorporated into the article in sheet form. The amorphous solid material in sheet form may be shredded and then incorporated into the article, suitably mixed into with an aerosolisable material, such as the sheet or shredded sheet of aerosolisable material described herein.
In further embodiments the amorphous solid sheet may additionally be incorporated as a planar sheet, as a gathered or bunched sheet, as a crimped sheet, or as a rolled sheet (i.e. in the form of a tube). In some such cases, the amorphous solid of these embodiments may be included in an aerosol-generating article as a sheet, such as a sheet circumscribing a rod comprising aerosolisable material. For example, the amorphous solid sheet may be formed on a wrapping paper which circumscribes an aerosolisable material such as tobacco.
The amorphous solid in sheet form may have any suitable area density, such as from about 30 g/m2 to about 150 g/m2. In some cases, the sheet may have a mass per unit area of about 55 g/m2 to about 135 g/m2, or about 80 to about 120 g/m2, or from about 70 to about 110 g/m2, or particularly from about 90 to about 110 g/m2, or suitably about 100 g/m2. These ranges can provide a density which is similar to the density of cut rag tobacco and as a result a mixture of these substances can be provided which will not readily separate. Such area densities may be particularly suitable where the amorphous solid material is included in an aerosol-generating article as a shredded sheet (described further hereinbelow). In some cases, the sheet may have a mass per unit area of about 30 to 70 g/m2, 40 to 60 g/m2, or 25 to 60 g/m2 and may be used to wrap an aerosolisable material, such as the aerosolisable material described herein.
The aerosol-generating material may comprise a blend of the aerosolisable material and the amorphous solid material as described herein. Such aerosol-generating material can provide an aerosol, in use, with a desirable flavour profile, since additional flavour may be introduced to the aerosol-generating material by inclusion in the amorphous solid material component. Flavour provided in the amorphous solid material may be more stably retained within the amorphous solid material compared to flavour added directly to the tobacco material, resulting in a more consistent flavour profile between articles produced according to this disclosure.
As described above, tobacco material having a density of at least 350 mg/cc and less than about 700 mg/cc has been advantageously found to result in a more sustained release of aerosol. To provide an aerosol having a consistent flavour profile the amorphous solid material component of the aerosol-generating material should be evenly distributed throughout the rod. The inventors have advantageously found that this can be achieved by casting the amorphous solid material to have a thickness as described herein, to provide an amorphous solid material having an area density which is similar to the area density of the tobacco material.
As noted above, optionally, the aerosol-generating material comprises a plurality of strips of amorphous solid material. Where the aerosol-generating section comprises a plurality of strands and/or strips of aerosolisable material and a plurality of strips of amorphous solid material, the material properties and/or dimensions of the at least two components may be suitably selected in other ways, to ensure a relatively uniform mix of the components is possible, and to reduce separation or un-mixing of the components during or after manufacture of the rod of aerosol-generating material.
The longitudinal dimension of the plurality of strands or strips may be substantially the same as a length of the aerosol-generating section. A number of the plurality of strands or strips may extend between a first end of the aerosol-generating section closest to the mouthpiece and a second end of the aerosol-generating section furthest away from the mouthpiece. The plurality of strands and/or strips may have a length of at least about 5 mm.
A temperature differential test procedure for a single wrapper is outlined below.
First, the wrapper to be tested is removed from the article. For instance, if the sample to be tested is a first plug wrap 7, the first plug wrap 7 is carefully cut from the article and is laid flat.
The sample is stored at ambient conditions for 24 hours. The ambient conditions are 22 degrees Celsius, standard atmospheric pressure (1 atm) and 60% relative humidity. The test procedure is conducted under these same ambient conditions.
Once the sample has been stored under the ambient conditions, the testing apparatus is prepared. That is, a Stuart™ US152 hotplate apparatus is operated such that the top plate of the apparatus is heated to 52.5 degrees Celsius, with the ‘Stir’ setting set to ‘off’. Also, a THERM-X™ XTMX3125 thermesthesiometer apparatus is prepared so that the probe of the thermesthesiometer is heated to 32 degrees Celsius.
The sample is then positioned flat against the top plate of the hotplate apparatus and the probe of the thermesthesiometer is pressed squarely against the sample with a force of 20 N. Thus, a first side of the sample is located against the top plate and is heated by the top plate, and the temperature of the opposite second side of the sample is measured by the probe of the thermesthesiometer. The temperature measured by the thermesthesiometer is recorded after 4 seconds of the sample being located against the top plate. The first side of the sample is the side of the wrapper that would usually be inwardly facing on the article 1 and the second side of the sample is the side of the wrapper that would usually be outwardly facing on the article 1.
The temperature differential ratio can then be calculated according to Equation 1 below:
In Equation 1, ‘Tdiff ratio’ is the temperature differential ratio; ‘Tplate’ is the temperature of the top plate (i.e. 52.5 degrees Celsius in the above test procedure); ‘Tprobe’ is the temperature of the second side of the sample measured by the probe after 4 seconds of positioning the sample against the heated plate; and, ‘Tambient’ is the ambient air temperature (i.e. 22 degrees Celsius in the above test procedure).
A higher temperature differential ratio is advantageous because it indicates that the sample provides a thermally insulative effect such that, in use of the article, the outer temperature of the sample is lower. Thus, a higher temperature differential ratio indicates that portion of the article comprising the sample will be cooler to touch.
Eleven samples from eleven different embodiments of article were subjected to the above temperature differential test procedure and the temperature differential ratio was calculated. The properties of each sample is summarised below and the results are recorded in Table 20.
Sample 1 is a tipping paper 5 that has a basis weight of 36 gsm, a thickness of 29 microns, and is substantially non-porous. The Tprobe value measured after 4 seconds was 45.7 degrees Celsius.
Sample 2 is a tipping paper 5 that has a basis weight of 36 gsm and a thickness of 32 microns, and is substantially non-porous. The Tprobe value measured after 4 seconds was 45.1 degrees Celsius.
Sample 3 is a paper first plug wrap 7 that has a basis weight of 27 gsm, a thickness of 38 microns, and is substantially non-porous. The Tprobe value measured after 4 seconds was 44.2 degrees Celsius.
Sample 4 is a paper first plug wrap 7 that has a basis weight of 31 gsm, a thickness of 35 microns, and is substantially non-porous The Tprobe value measured after 4 seconds was 45.4 degrees Celsius.
Sample 5 is a paper first plug wrap 7 that has a basis weight of 35 gsm, a thickness of 49 microns, and is substantially non-porous. The Tprobe value measured after 4 seconds was 43.9 degrees Celsius.
Sample 6 is a paper first plug wrap 7 that has a basis weight of 70 gsm, a thickness of 90 microns, and is substantially non-porous. The Tprobe value measured after 4 seconds was 43.2 degrees Celsius.
Sample 7 is a paper first plug wrap 7 that has a basis weight of 100 gsm, a thickness of 121 microns, and is substantially non-porous. The Tprobe value measured after 4 seconds was 42.1 degrees Celsius.
Sample 8 is a paper first plug wrap 7 that has a basis weight of 21 gsm, a thickness of 55 microns and is porous, with a permeability of 24000 Coresta Units. The Tprobe value measured after 4 seconds was 43.5 degrees Celsius.
Sample 9 is a paper first plug wrap 7 that has a basis weight of 25 gsm, a thickness of 65 microns and is porous, with a permeability of 12000 Coresta Units. The Tprobe value measured after 4 seconds was 42.7 degrees Celsius.
Sample 10 is an embossed paper first plug wrap 7. Sample 10 is a fluted paper comprising a plurality of grooves that extend in a direction parallel to the central axis of the article. Prior to fluting, the sheet material of sample 10 has a thickness of 13 microns and a basis weight of 176 gsm. After embossing, sample 10 has a maximum thickness of 50 microns. Sample 10 is substantially non-porous. The Tprobe value measured after 4 seconds was 35.6 degrees Celsius.
Sample 11 is an embossed paper first plug wrap 7. Sample 11 is embossed to have a honeycomb pattern as shown in
As can be observed from the results in Table 20, the Tprobe measured after 4 seconds decreases with increased basis weight of the sample, thereby lowering the temperature differential ratio. Increasing the thickness of the sample also decreases the Tprobe value, and the effect of the thickness on the Tprobe value has been observed to be more pronounced than the effect of the basis weight on the Tprobe value. Embossing the sample can also be seen to reduce the Tprobe value, as can be observed from samples 10 and 11. This is due to the insulative effect of the air gaps that are created embossing.
It should be noted that the samples being non-porous refers to the samples having a permeability of less than 100 Coresta Units.
It should also be noted that although samples 1 and 2 are indicated as being the tipping paper 5, and samples 3 to 11 are indicated as being the first plug wrap 7, wrappers having the specifications of any of the above samples could be used as a tipping paper 5, first plug wrap 7 or second plug wrap 9, or another wrapper of the article.
In some embodiments, an article for a non-combustible aerosol provision system, wherein the article comprises an aerosol generating material, a downstream portion downstream of the aerosol generating material, and a wrapper, wherein the wrapper is configured such that if the wrapper is subjected to the temperature differential test procedure for a single wrapper as described above then the temperature differential ratio is at least 0.2.
In some embodiments, the wrapper comprises paper.
In some embodiments, the wrapper has a basis weight of at least 20 gsm and, preferably, at least 25, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 150 or 170 gsm.
In some embodiments, the wrapper has a basis weight of at most 180 gsm and, preferably, at most 170, 160, 150, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30 or 25 gsm.
In some embodiments, the wrapper has a thickness of at least 20 microns and preferably, has a thickness of at least 30, 40, 50, 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600 microns.
In some embodiments, the wrapper has a thickness of at most 650 microns and preferably, has a thickness of at most 600, 550, 500, 450, 400, 350, 300, 250, 200, 150, 100, 50, 40 or 30 microns.
In some embodiments, the wrapper is substantially non-porous.
In some embodiments, the wrapper is porous.
In some embodiments, the wrapper has a permeability of at least 100 Coresta Units and, preferably, at least 500, 1000, 2000, 5000, 10000, 12000, 15000, 17000, 20000, 22000 or 25000 Coresta Units.
In some embodiments, the wrapper is configured such that if the wrapper is subjected to the temperature differential test procedure for a single wrapper as set out herein then the temperature differential ratio is at least 0.22 and, preferably, at least 0.25, 0.3, 0.35, 0.4, 0.45, 0.5 or 0.55.
In some embodiments, the wrapper is a plug wrap.
In some embodiments, the wrapper is a tipping wrapper that attaches the downstream portion to the aerosol generating material.
In some embodiments, the wrapper is the first plug wrap 7, second plug wrap 9 or tipping paper 5 of one of the articles 1, 1′ described herein.
In some embodiments, the article comprises a collation of wrappers. For example, in the embodiment shown in
The temperature differential test procedure for a collation of wrappers is as follows. First, the collation of wrappers to be tested is removed from the article. For instance, if the article comprises a first plug wrap 7, a second plug wrap 9 that overlies the first plug wrap 7, and a tipping paper 5 that overlies the second plug wrap 9, then each of the wrappers 5, 7, 9 are carefully cut from the article and are laid flat such that they overlie each other in the same as order that the wrappers 5, 7, 9 overlap on the article. Thus, for example, for the article 1 of
The principle is the same if the collation of wrappers comprises a different number of wrappers. For example, if the collation comprises four wrappers then the four wrappers are removed from the article and are laid flat in the same order that the wrappers overlie each other when in position on the article.
The collation of wrapper samples are then stored at ambient conditions for 24 hours. Ambient conditions are 22 degrees Celsius, atmospheric pressure and 60% relative humidity. The test procedure is conducted under these same ambient conditions.
Once the collation of samples has been stored under the ambient conditions, the testing apparatus is prepared. That is, a Stuart™ US152 hotplate apparatus is operated such that the top plate of the apparatus is heated to 52.5 degrees Celsius, with the ‘Stir’ setting set to ‘off’. Also, a THERM-X™ XTMX3125 thermesthesiometer apparatus is prepared so that the probe of the thermesthesiometer is heated to 32 degrees Celsius.
The collation of samples is then positioned flat against the top plate of the hotplate apparatus and the probe of the thermesthesiometer is pressed squarely against the sample with a force of 20 N. The collation of samples is positioned against the top plate in the same order that the wrappers are positioned on the article. The side of the collation that usually forms the innermost layer of the wrappers when in place on the article is located against the top plate and is heated by the top plate. The temperature of the opposite second side of the collation of samples is measured by the probe of the thermesthesiometer. The temperature measured by the thermesthesiometer is recorded after 4 seconds of the collation of samples being located against the top plate.
For example, in testing the collation of wrappers 5,7,9 of the article of
It should be noted that the probe reading is taken at a position wherein all layers of the collation of samples that overlap on the article are located between the top plate and the probe. For instance, if the collation of wrappers comprises three wrappers that overlap when located on the article, then all three wrappers overlie each other and are located between the probe and the heated top plate.
The temperature differential ratio can then be calculated according to Equation 1 above, wherein ‘Tdiff ratio’ is the temperature differential ratio; ‘Tplate’ is the temperature of the top plate (i.e. 52.5 degrees Celsius in the above test procedure); ‘Tprobe’ is the temperature of the second side of the collation of samples measured by the probe after 4 seconds of positioning the collation of samples against the heated plate; and, ‘Tambient’ is the ambient air temperature (i.e. 22 degrees Celsius in the above test procedure).
A higher temperature differential ratio is advantageous because it indicates that the collation of samples provides an insulative effect such that, in use of the article, the outer temperature of the collation of wrappers is lower.
Eight collations of wrappers from eight different embodiments of article were subjected to the above temperature differential test procedure and the temperature differential ratio was calculated. The properties of each collation of samples is summarised below and the results are recorded in Table 21. Each of the collations is taken from an article having a configuration of wrappers of as shown in
Collation 1 comprises a first plug wrap 7 according to sample 3 above, a second plug wrap 9 according to sample 3 above and a tipping paper 5 according to sample 1 above. Thus, collation 1 comprises a paper first plug wrap 7 that has a basis weight of 27 gsm, a thickness of 38 microns, and is substantially non-porous (i.e. sample 3). Furthermore, collation 1 comprises a paper second plug wrap 9 that has a basis weight of 27 gsm, a thickness of 38 microns, and is substantially non-porous (i.e. sample 3). Moreover, collation 1 comprises a tipping paper 5 that has a basis weight of 36 gsm, a thickness of 29 microns, and is substantially non-porous (i.e. sample 1). The Tprobe value measured after 4 seconds was 42.8 degrees Celsius.
Collation 2 comprises a first plug wrap 7 according to sample 5 above, a second plug wrap 9 according to sample 5 above and a tipping paper 5 according to sample 1 above. The Tprobe value measured after 4 seconds was 42 degrees Celsius.
Collation 3 comprises a first plug wrap 7 according to sample 6 above, a second plug wrap 9 according to sample 6 above and a tipping paper 5 according to sample 1 above. The Tprobe value measured after 4 seconds was 40.2 degrees Celsius.
Collation 4 comprises a first plug wrap 7 according to sample 8 above, a second plug wrap 9 according to sample 8 above and a tipping paper 5 according to sample 1 above. The Tprobe value measured after 4 seconds was 40.3 degrees Celsius.
Collation 5 comprises a first plug wrap 7 according to sample 9 above, a second plug wrap 9 according to sample 9 above and a tipping paper 5 according to sample 1 above. The Tprobe value measured after 4 seconds was 39.8 degrees Celsius.
Collation 6 comprises a first plug wrap 7 according to sample 3 above, a second plug wrap 9 according to sample 8 above and a tipping paper 5 according to sample 1 above. The Tprobe value measured after 4 seconds was 41.3 degrees Celsius.
Collation 1 comprises a first plug wrap 7 according to sample 8 above, a second plug wrap 9 according to sample 3 above and a tipping paper 5 according to sample 1 above. The Tprobe value measured after 4 seconds was 41.2 degrees Celsius.
Collation 8 comprises a first plug wrap 7 according to sample 10 above, a second plug wrap 9 according to sample 9 above and a tipping paper 5 according to sample 1 above. The Tprobe value measured after 4 seconds was 35.4 degrees Celsius.
In some embodiments, there is provided an article comprising an aerosol generating material, a downstream portion downstream of the aerosol generating material, and a plurality of wrappers that form a collation of wrappers, wherein the collation of wrappers is configured such that if the collation of wrappers is subjected to the temperature differential test procedure for a collation of wrappers as set out herein then the temperature differential ratio is at least 0.3.
In some embodiments, the collation of wrappers is configured such that if the collation of wrappers is subjected to the temperature differential test procedure for a collation of wrappers as set out herein then the temperature differential ratio is at least 0.32 and, preferably, at least 0.35, 0.4, 0.45, 0.5, 0.55 or 0.6.
In some embodiments, at least one wrapper of the collation of wrappers comprises paper.
In some embodiments, at least one wrapper of the collation of wrappers has a basis weight of at least 20 gsm and, preferably, at least 25, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 150 or 170 gsm.
In some embodiments, at least one wrapper of the collation of wrappers has a basis weight of at most 180 gsm and, preferably, at most 170, 160, 150, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30 or 25 gsm.
In some embodiments, at least one wrapper of the collation of wrappers has a thickness of at least 20 microns and preferably, has a thickness of at least 30, 40, 50, 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600 microns.
In some embodiments, at least one wrapper of the collation of wrappers has a thickness of at most 650 microns and preferably, has a thickness of at most 600, 550, 500, 450, 400, 350, 300, 250, 200, 150, 100, 50, 40 or 30 microns.
In some embodiments, at least one wrapper of the collation of wrappers is substantially non-porous.
In some embodiments, at least one wrapper of the collation of wrappers is porous.
In some embodiments, at least one wrapper of the collation of wrappers has a permeability of at least 100 Coresta Units and, preferably, at least 500, 1000, 2000, 5000, 10000, 12000, 15000, 17000, 20000, 22000 or 25000 Coresta Units.
In some embodiments, at least one wrapper of the collation of wrappers is configured such that if the wrapper is subjected to the temperature differential test procedure for a single wrapper as set out herein then the temperature differential ratio is at least 0.2 and, preferably, at least 0.22, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5 or 0.55.
In some embodiments, the collation of wrappers comprises a first wrapper and, preferably, the first wrapper has the features of the wrapper described above.
In some embodiments, the first wrapper circumscribes a component of the article and, preferably, wherein the component is a tube or plug of material of the article.
In some embodiments, the first wrapper contacts the component of the article.
In some embodiments, the collation of wrappers comprises a second wrapper and, preferably, the second wrapper has the features of the wrapper described above.
In some embodiments, the second wrapper connects the downstream portion to the aerosol generating material.
In some embodiments, the second wrapper is an outermost wrapper of the article.
In some embodiments, the collation of wrappers comprises a third wrapper and, preferably, the third wrapper has the features of the wrapper described above.
In some embodiments, the third wrapper is configured to connect first and second components of the article.
In some embodiments, the third wrapper is located between the first and second wrappers.
In some embodiments, the first wrapper is a first plug wrap 7, the second wrapper is a tipping paper 5 and the third wrapper is a second plug wrap 9 according to one of the articles 1, 1′ described above
The device 100 comprises a housing 102 (in the form of an outer cover) which surrounds and houses various components of the device 100. The device 100 has an opening 104 in one end, through which the article 110 may be inserted for heating by a heating assembly. In use, the article 110 may be fully or partially inserted into the heating assembly where it may be heated by one or more components of the heater assembly.
When the article 110 is inserted into the device 100, the minimum distance between the one or more components of the heater assembly and a tubular body 4a of the article 110 may be in the range 3 mm to 10 mm, for example 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm or 10 mm.
The device 100 of this example comprises a first end member 106 which comprises a lid 108 which is moveable relative to the first end member 106 to close the opening 104 when no article 110 is in place. In
The device 100 may also include a user-operable control element 112, such as a button or switch, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the switch 112.
The device 100 may also comprise an electrical component, such as a socket/port 114, which can receive a cable to charge a battery of the device 100. For example, the socket 114 may be a charging port, such as a USB charging port.
As shown in
The end of the device closest to the opening 104 may be known as the proximal end (or mouth end) of the device 100 because, in use, it is closest to the mouth of the user. In use, a user inserts an article 110 into the opening 104, operates the user control 112 to begin heating the aerosol generating material and draws on the aerosol generated in the device. This causes the aerosol to flow through the device 100 along a flow path towards the proximal end of the device 100.
The other end of the device furthest away from the opening 104 may be known as the distal end of the device 100 because, in use, it is the end furthest away from the mouth of the user. As a user draws on the aerosol generated in the device, the aerosol flows away from the distal end of the device 100.
The device 100 further comprises a power source 118. The power source 118 may be, for example, a battery, such as a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, a lithium battery (such as a lithium-ion battery), a nickel battery (such as a nickel-cadmium battery), and an alkaline battery. The battery is electrically coupled to the heating assembly to supply electrical power when required and under control of a controller (not shown) to heat the aerosol generating material. In this example, the battery is connected to a central support 120 which holds the battery 118 in place.
The device further comprises at least one electronics module 122. The electronics module 122 may comprise, for example, a printed circuit board (PCB). The PCB 122 may support at least one controller, such as a processor, and memory. The PCB 122 may also comprise one or more electrical tracks to electrically connect together various electronic components of the device 100. For example, the battery terminals may be electrically connected to the PCB 122 so that power can be distributed throughout the device 100. The socket 114 may also be electrically coupled to the battery via the electrical tracks.
In the example device 100, the heating assembly is an inductive heating assembly and comprises various components to heat the aerosol generating material of the article 110 via an inductive heating process. Induction heating is a process of heating an electrically conducting object (such as a susceptor) by electromagnetic induction. An induction heating assembly may comprise an inductive element, for example, one or more inductor coils, and a device for passing a varying electric current, such as an alternating electric current, through the inductive element. The varying electric current in the inductive element produces a varying magnetic field. The varying magnetic field penetrates a susceptor suitably positioned with respect to the inductive element, and generates eddy currents inside the susceptor. The susceptor has electrical resistance to the eddy currents, and hence the flow of the eddy currents against this resistance causes the susceptor to be heated by Joule heating. In cases where the susceptor comprises ferromagnetic material such as iron, nickel or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e. by the varying orientation of magnetic dipoles in the magnetic material as a result of their alignment with the varying magnetic field. In inductive heating, as compared to heating by conduction for example, heat is generated inside the susceptor, allowing for rapid heating. Further, there need not be any physical contact between the inductive heater and the susceptor, allowing for enhanced freedom in construction and application.
The induction heating assembly of the example device 100 comprises a susceptor arrangement 132 (herein referred to as “a susceptor”), a first inductor coil 124 and a second inductor coil 126. The first and second inductor coils 124, 126 are made from an electrically conducting material. In this example, the first and second inductor coils 124, 126 are made from Litz wire/cable which is wound in a helical fashion to provide helical inductor coils 124, 126. Litz wire comprises a plurality of individual wires which are individually insulated and are twisted together to form a single wire. Litz wires are designed to reduce the skin effect losses in a conductor. In the example device 100, the first and second inductor coils 124, 126 are made from copper Litz wire which has a rectangular cross section. In other examples the Litz wire can have other shape cross sections, such as circular.
The first inductor coil 124 is configured to generate a first varying magnetic field for heating a first section of the susceptor 132 and the second inductor coil 126 is configured to generate a second varying magnetic field for heating a second section of the susceptor 132. In this example, the first inductor coil 124 is adjacent to the second 20) inductor coil 126 in a direction along the longitudinal axis 134 of the device 100 (that is, the first and second inductor coils 124, 126 to not overlap). The susceptor arrangement 132 may comprise a single susceptor, or two or more separate susceptors. Ends 130 of the first and second inductor coils 124, 126 can be connected to the PCB 122.
It will be appreciated that the first and second inductor coils 124, 126, in some examples, may have at least one characteristic different from each other. For example, the first inductor coil 124 may have at least one characteristic different from the second inductor coil 126. More specifically, in one example, the first inductor coil 124 may have a different value of inductance than the second inductor coil 126. In
In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful when the inductor coils are active at different times. For example, initially, the first inductor coil 124 may be operating to heat a first section/portion of the article 110, and at a later time, the second inductor coil 126 may be operating to heat a second section/portion of the article 110. Winding the coils in opposite directions helps reduce the current induced in the inactive coil when used in conjunction with a particular type of control circuit. In
The susceptor 132 of this example is hollow and therefore defines a receptacle within which aerosol generating material is received. For example, the article 110 can be inserted into the susceptor 132. In this example the susceptor 120 is tubular, with a circular cross section.
The susceptor 132 may be made from one or more materials. Preferably the susceptor 132 comprises carbon steel having a coating of Nickel or Cobalt.
In some examples, the susceptor 132 may comprise at least two materials capable of being heated at two different frequencies for selective aerosolization of the at least two materials. For example, a first section of the susceptor 132 (which is heated by the first inductor coil 124) may comprise a first material, and a second section of the susceptor 132 which is heated by the second inductor coil 126 may comprise a second, different material. In another example, the first section may comprise first and second materials, where the first and second materials can be heated differently based upon operation of the first inductor coil 124. The first and second materials may be adjacent along an axis defined by the susceptor 132, or may form different layers within the susceptor 132. Similarly, the second section may comprise third and fourth materials, where the third and fourth materials can be heated differently based upon operation of the second inductor coil 126. The third and fourth materials may be adjacent along an axis defined by the susceptor 132, or may form different layers within the susceptor 132. Third material may the same as the first material, and the fourth material may be the same as the second material, for example. Alternatively, each of the materials may be different. The susceptor may comprise carbon steel or aluminium for example.
The device 100 of
The insulating member 128 can also fully or partially support the first and second inductor coils 124, 126. For example, as shown in
In a specific example, the susceptor 132, the insulating member 128, and the first and second inductor coils 124, 126 are coaxial around a central longitudinal axis of the susceptor 132.
The device 100 further comprises a support 136 which engages one end of the susceptor 132 to hold the susceptor 132 in place. The support 136 is connected to the second end member 116.
The device may also comprise a second printed circuit board 138 associated within the control element 112.
The device 100 further comprises a second lid/cap 140 and a spring 142, arranged towards the distal end of the device 100. The spring 142 allows the second lid 140 to be opened, to provide access to the susceptor 132. A user may open the second lid 140 to clean the susceptor 132 and/or the support 136.
The device 100 further comprises an expansion chamber 144 which extends away from a proximal end of the susceptor 132 towards the opening 104 of the device. Located at least partially within the expansion chamber 144 is a retention clip 146 to abut and hold the article 110 when received within the device 100. The expansion chamber 144 is connected to the end member 106.
In one example, the susceptor 132 has a wall thickness 154 of about 0.025 mm to 1 mm, or about 0.05 mm.
In one example, the susceptor 132 has a length of about 40 mm to 60 mm, about 40 mm to 45 mm, or about 44.5 mm.
In one example, the insulating member 128 has a wall thickness 156 of about 0.25 mm to 2 mm, 0.25 mm to 1 mm, or about 0.5 mm.
In use, the articles 1, 1′ described herein can be inserted into a non-combustible aerosol provision device such as the device 100 described with reference to
The articles 1, 1′ described herein have particular advantages, for instance when used with non-combustible aerosol provision devices such as the device 100 described with reference to
The hollow tubular element of the mouthpiece 2′ has also been found to have a significant influence on the temperature of the outer surface of the mouthpiece 2′ of the article 1′. For instance, where the hollow tubular element 8 formed from filamentary tow is wrapped in an outer wrapper, for instance the tipping paper 5, an outer surface of the outer wrapper at a longitudinal position corresponding to the location of the hollow tubular element 8 has been found to reach a maximum temperature of less than 42° C. during use, suitably less than 40° C. and more suitably less than 38° C. or less than 36° C.
Referring now to
As shown in
The area 202 is arranged to receive the article 1. When the article 1 is received into the area 202, at least a portion of the aerosol-generating material comes into thermal proximity with the heater 203. When the article 1 is fully received in the area 202, at least a portion of the aerosol-generating material may be in direct contact with the heater 203. The aerosol-forming substrate will release a range of volatile compounds at different temperatures. By controlling the maximum operation temperature of the electrically heated aerosol generating system 200, the selective release of undesirable compounds may be controlled by preventing the release of select volatile compounds.
As shown in
The housing 201 of non-combustible aerosol provision device defines an area 202 in the form of a cavity, open at the proximal end (or mouth end), for receiving an aerosol-generating article 1 for consumption. The distal end of the cavity is spanned by a heating assembly comprising a heater 203. The heater 203 is retained by a heater mount (not shown) such that an active heating area of the heater is located within the cavity. The active heating area of the heater 203 is positioned within the aerosol-generating section of the aerosol-generating article 1 when the aerosol-generating article 1 is fully received within the cavity.
The heater 203 is shaped in the form of a blade terminating in a point. That is, the heater has a length dimension that is greater than its width dimension, which is greater than its thickness dimension. First and second faces of the heater are defined by the width and length of the heater.
As the article 1 is pushed into the cavity, the tapered point of the heater engages with the aerosol-generating material 3. The blade is shaped for easy insertion and removal from an aerosol-generating material 3. By applying a force to the article 1, the heater penetrates into the aerosol-generating material 3. When the article 1 is properly engaged with the non-combustible aerosol provision device, the heater 203 is inserted into the aerosol-generating material 3. When the heater is actuated, aerosol-generating material 3 is warmed and volatile substances are generated or evolved. As a user draws on the mouthpiece 2, air is drawn into the article 1 and the volatile substances condense to form an inhalable aerosol. This aerosol passes through the mouthpiece 2 of the article 1 and into the user's mouth.
The inventors have found that, when the aerosol-generator is inserted into a consumable comprising the aerosol-generating material described herein, the aerosol-generator is better retained by the aerosol-generating material.
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.
The following clauses form part of the disclosure:
| Number | Date | Country | Kind |
|---|---|---|---|
| 1919104.8 | Dec 2019 | GB | national |
| 2009164.1 | Jun 2020 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/GB2020/053339 | 12/21/2020 | WO |
