The present invention relates to methods, compositions and apparatus for generating a functionalized aerosol which emulates the organoleptic characteristics and properties of mainstream smoke generated by traditional tobacco-based smoking articles.
Electronic cigarettes are a popular alternative to traditional smoking articles that burn tobacco products to generate mainstream smoke for inhalation. Unlike traditional tobacco-based smoking articles, electronic cigarettes generate an aerosol-based vapor for inhalation which generally emulates mainstream smoke of traditional tobacco based smoking articles. However, it is generally recognized that aerosol-based vapor generated by electronic cigarettes does not deliver the same “quality” of experience as traditional smoking articles. Applicants have found that this deficiency in the “quality” of experience results, at least in part, from the use of a composite aerosol forming liquid solution to generate the aerosol-based vapor. More specifically, the composite aerosol forming liquid solution includes an aerosol forming liquid and one or more taste, fragrance or nicotine delivery compositions. Among other things, it is believed that the use of such a composite aerosol forming liquid solution may result in the formation of chemically or pharmacological incompatible components. Furthermore, it is believed that interactions among the various components of the composite aerosol forming liquid solution may cause chemical, pharmacological, and/or thermal instability, which, in turn, may result in particulate precipitation, fouling of the aerosol heating element or chemical degradation of the solution, as well as other constraints to aerosol vapor delivery. Each of these deficiencies compromises the organoleptic performance and quality of the aerosol based vapor generated by the electronic cigarettes. Accordingly, it is desirable to provide improved methods, compositions and apparatus for generating functionalized aerosols having enhanced organoleptic characteristics and properties which more closely emulate the smoking experience provided by the mainstream smoke from traditional tobacco-based smoking articles.
An objective of the invention is to provide a method, composition and apparatus for generating a functionalized flavor aerosol vapor which emulates the organoleptic characteristics and properties of mainstream smoke experienced by users smoking traditional tobacco-based smoking articles.
In one embodiment, an apparatus for generating a functionalized aerosol can comprise a battery section comprising a first housing, a battery disposed within the first housing, and a first connector coupled to the housing, an aerosol section comprising a second housing, an aerosol forming chamber disposed within the second housing, and a pod bay, and an insert section comprising a third housing, a connector, and a mouth end. The battery section can be configured to couple to the aerosol section, the aerosol section can be configured to couple to the insert section, and the connector can be configured to fit within the pod bay.
In another embodiment, an apparatus for generating a functionalized aerosol can comprise a battery section comprising a first housing, a battery disposed within the first housing, and a first connector coupled to the housing, an aerosol section comprising a second housing, an aerosol forming chamber disposed within the second housing, and a pod bay, and an insert section comprising a third housing, a pod bay, a separator, a flavor reservoir, a mouth end, and a through-hole. The battery section can be configured to couple to the aerosol section, the aerosol section can be configured to couple to the insert section, and the connector can be configured to fit within the pod bay.
Furthermore, with respect to electronic cigarettes based on tank configurations, if the users want to change flavors they either have to use multiple tanks or subject the tank to inconvenient cleaning procedures. This limits the flexibility of simple tank electronic cigarettes.
It is a further objective of the invention to provide a method comprising a two-step process for the formation of a functionalized aerosol vapor. The first step of the process involves generating an aerosol from an aerosol forming liquid. The second step of the process involves functionalizing the aerosol by subjecting the aerosol to a matrix for the purpose of transferring, delivering or imparting one or more organoleptic properties such as taste, fragrance and/or nicotine delivery to the aerosol.
It is yet a further objective of the present invention to provide a method wherein the first step of generating an aerosol comprises providing an optimal aerosol density for the desired fragrance, taste, and/or nicotine delivery properties subsequently imparted on the aerosol in the second step of the process.
It is yet a further objective of the present invention to provide a method wherein the first step of the process comprises generating an aerosol having properties for optimizing the taste, fragrance and/or nicotine delivery characteristics to the aerosol during the second step of the inventive method. For example, the aerosol forming liquid may comprise an excipient such as water which forms an aerosol having properties for activating exothermic or endothermic reactions during the second step of the process.
It is yet another objective of the present invention to provide a method wherein the aerosol vapor pressure is used as a mechanism for transferring, delivering or imparting taste, fragrance and/or nicotine characteristics during the second step of the process.
It is yet a further objective of this invention to provide an aerosol-forming composition and a separate functional composition for generating a functionalized aerosol vapor with emulates the organoleptic characteristics and properties of mainstream smoke experienced by smoking traditional tobacco-based smoking articles. For example, the aerosol-forming composition may comprise ethanol, glycerol, propylene glycol, polyethylene glycol, water, nicotine, or mixtures thereof. The functional composition may comprise one or more organoleptic components such as taste, fragrance, and/or nicotine delivery components. For example, the functional composition may comprise a solution or dispersion having taste and/or nicotine delivery components. Alternatively, the functional composition may comprise encapsulated taste and/or fragrance delivery components. Moreover, the functional composition may comprise a gel having taste, fragrance and/or nicotine delivery components.
According to another aspect of the present invention, the taste, fragrance and/or nicotine composition may comprise a vapor pressure modifier such as ethanol.
It is yet a further objective of the present invention to provide an apparatus for generating a functionalized aerosol vapor which emulates the organoleptic characteristics and properties of mainstream smoke experienced by smoking traditional tobacco-based smoking articles. In one embodiment, the apparatus comprises a first chamber or zone containing an aerosol-forming liquid which is adapted to deliver aerosol-forming liquid to a heating device. The apparatus further comprises a downstream chamber or zone containing an functional composition comprising one or more organoleptic components such as a taste, fragrance and/or nicotine delivery components.
It is yet a further objective of this invention to provide a flavor insert for imparting flavor to an aerosol.
According to one aspect of the present invention, a two-step process is used to form an aerosol with organoleptic properties suitable to be delivered with e-cigarettes. In the first step of the process, an aerosol is formed from a non-flavored formulation located in a first chamber or zone of the e-cigarette. Any aerosol formation mechanism (e.g., thermal, mechanical, piezoelectric) may be used in the present invention. The aerosol is then subjected to a taste, fragrance and/or nicotine carrying matrix adapted to transfer the desired organoleptic properties to the aerosol. During this step, taste, fragrance and/or nicotine delivery components in a high vapor pressure solvent are released into the aerosol prior to exiting the e-cigarette mouth piece.
The formation of an unflavored aerosol in an e-cigarette may involve any known nebulizer mechanism. For example, ultrasonic wave nebulization (with a piezoelectric element vibrating and creating high-frequency ultrasound waves to cause vibrations and atomization of liquid formulations), electric nebulization (with a heating element built on a high surface component in direct contact with an aerosol forming material), or spraying jet atomization by passing an aerosol solution through small venturi injection channels. In general, the aerosol characteristics depend on the rheological and thermodynamics properties of the aerosol forming liquid as well as the nebulization mechanism. Because of physical chemical stresses (i.e. thermal degradation, shear induced phase separation, etc.) of the aerosol forming material during nebulization, the aerosol characteristics and delivery consistency can be affected when the liquid is nebulized. This is very relevant to aerosol quality if the affected aerosol material component is organoleptic. For example, nicotine might degrade under thermal nebulization; menthol and other hydrophobic taste material might precipitate due to incompatibility with hydrophilic forming aerosol formulations. In other cases, desirable organoleptic materials, i.e. menthol, tobacco flavors, etc., can be insoluble in the aerosol forming liquid at the appropriate viscosity and/or surface tension to deliver an acceptable aerosol, therefore, limiting the amount of delivered organoleptic. Furthermore, improvements to the consistency of aerosol delivery might be possible with this strategy because the organoleptic material—which are absent during aerosol formation—would not affect the viscosity and the surface tension. These material variables affect aerosol particle size distribution. Having an aerosol formation process prior to flavoring insures aerosol consistency, in particular, when it is desirable to deliver a consistent nicotine amount by the aerosol exiting the mouth piece of the e-cigarette.
Therein, that an unflavored aerosol formulation, located in the first chamber or zone, suitable to form aerosols with particle size distribution and/or density and deliver desired user experience, and that can be later further tailored for organoleptic delivery is attractive to e-cigarette manufacturers. Base aerosol formulations suitable for the present invention comprise aerosol forming materials, vapor pressure modifiers, buffers, salts, nucleation site structures, surfactants, preservatives, and an excipient. Furthermore, any of the components that form the unflavored aerosol formulation can be used to trigger chemically another component located downstream the nebulizer. For example, water can be used to activate exothermic or endothermic reactions of salts located in a downstream insert to induce heat changes that either heat a sublimable material insert or change deliverable aerosol particle size distribution. Non-limiting examples of unflavored aerosol forming formulations are included in Table I below.
Taste, fragrance and/or nicotine carrying matrix formulations, applicable to this invention to change the organoleptic properties of the delivered aerosol are presented in the embodiments below. These formulations can be liquids, dispersions, gels, encapsulate fragrances, fibers or any other forms and shapes that allow intimate contact with the unflavored aerosol stream. These formulations may have a high vapor pressure to allow maximizing their fragrance contribution to the aerosol stream. Illustrative examples of functionalized formulations which may be incorporated in the e-cigarette are presented below.
Fragrance Delivery
The major formulation components in this embodiment, when the formulation is in a liquid state, consist of a fragrance, a vapor pressure modifier, a preservative and an excipient. These formulations might also contain other components to further modify the delivered aerosol stream such as surfactants, nucleation sites, buffers, etc. Table II shows non-limiting examples for solutions, dispersions, encapsulates and gel formulation physical forms. These formulations might contain nicotine as required by a final aerosol delivery specification.
Low Solubility/Hydrophobic Organoleptic Fragrance Delivery
When the solubility of the organoleptic material is low, there is a limit to the amount of organoleptic in an aerosol compatible formulation. By placing the organoleptic downstream from the aerosol forming part of the e-cigarette, it is possible to have formulations with high concentration of delivered organoleptics since they are not constrained by their low solubility in aerosol forming formulations. The formulation components in this embodiment can consist of a fragrance, a vapor pressure modifier, a preservative and an excipient. These formulations might also contain other components to further modify the delivered aerosol stream such as surfactants, nucleation sites, buffers, etc. The table below shows non-limiting examples for liquids, solutions and dispersions.
Low Solubility/Hydrophobic Organoleptic Fragrance Delivery
A. Chemical/Thermal Aerosol Delivery Activation
Because in the practice of this invention two or more chambers, compartments or zones are used having different formulations, the invention also enables benefits resulting from their different nature to obtain further improvements in aerosol delivery. These improvements are inclusive for the embodiments disclosed in Table I, II and III above. Two specific cases are noted below:
1. Chemical Equilibrium or Chemical Reactivity Activation
According to this embodiment, the unflavored formulation may comprise a chemical component that can either react or affect another chemical component included in the downstream functionalized formulation. For example, it is known that nicotine in solution is in a chemical equilibrium as per the Bronsted-Lowry acid/base theory. Therefore, acidic or basic component—such as acetic, citric, etc., buffers—carried by the unflavored aerosol can be useful to control the ionization of nicotine in the final delivered aerosol. Therein, according to this embodiment, improvement in nicotine delivery consistency is possible. In addition, the formation in situ of fragile flavors and taste component is possible if reactants are kept separated until mixing in the aerosol vapor prior to delivery.
2. Thermal Activation
The inclusion of a chemical component in the unflavored formulation that can react with another chemical component included in the downstream formulation to exothermically or endothermically change the temperature of the aerosol. For example, water in the unflavored aerosol can react with a salt pod in the downstream portion of the e-cigarette to release heat of hydration, i.e., food grade Fe and Mn salts, CaO, etc. This heat can be used to assist in the sublimation of organoleptic in the downstream portion of the e-cigarette. Another example is the use of an endothermic reaction, i.e., food grade NH4Cl, etc. This would allow cooling of the aerosol vapor after its formation and therefore improve delivery consistency of the aerosol particle size distribution.
This concept separates aerosol formation from taste, fragrance and/or nicotine delivery. Therefore, the aerosol is improved by removing any degradation of quality, nicotine delivery and taste caused by either the interaction of the aerosol forming liquid formulation with the formulation contained in the fragrance insert or its thermal degradation/inactivation when in contact with the heating element of the e-cigarette.
In addition, the fragrance formulations in the inserts can be made with a broad range of materials such as normal solutions, dispersions, emulsions, gels, creams, powders, pastes, waxes, etc. The fragrance release can occur thermally, chemically, dissolution, vapor pressure driven, moisture, electric, etc. The insert can use fabricated using one or combination of different fragrance matrixes such as surface coating, dissolvable and non-dissolvable matrix, encapsulated fragrance, fibers, porous materials, wicking web, coated web, etc.
Although, this concept is based on aerosol flow dynamics, it can be further enhanced by placing a heating element in the insert to control the release of fragrance.
An embodiment of an apparatus of the present invention depicted below in
The sketches proved in the following figures illustrate numerous embodiments of the proposed inserts for the practice of the present invention. These embodiments are non-limiting, and it will be understood that the present invention may comprise combinations of one or more of these embodiments that might be integrated into an electronic cigarette or manufactured as modular or removable.
Porous Matrix of Embedded Coated Fibers or Hollow Fibers Filled with Fragrance Formulations
Single/Multiple Layer Screen Insert Where the Screen Carries Fragrances as Coated Fibers, Fragrances as Encapsulated Fibers, Etc.
Woven or Non-Woven Web or Sheet Form with Erodible Material or any of the Previously Described Fragrance Carriers
Diffusible and/or Erodible Disk(s)
Coil Wrapped Insert with a Coated High Area or Webbed Structure
Porous Membrane or Open Cell Foam/Sponge
Plaited Flavor Coated Insert
3-Dimensional Flavor Coated Insert
Tube Bundles
Fragrance/Nicotine Coated Channel in a Honeycomb Insert
Fragrance Release by Inhalation—I
Fragrance Release by Inhalation or Physically Crushed—II
Fragrance Releasing Non-Web/Web Pouch
Fragrance Releasing Pouch
The aerosol section 202 can comprise a second housing, a heater 211, an aerosol forming compound 213, an airflow path 212, an aerosol section distal connector 210, and an aerosol section proximal connector 215. The second housing 214 can comprise a metal alloy, a plastic, or the like. In one embodiment, the aerosol forming compound 213, the heater 211, and the airflow path 212 can be surrounded by and within an interior of the second housing 214. The aerosol section distal connector can be sized and configured to connect to the battery connector 207. In one embodiment one of the connectors can form a screw thread and the other connector can form a screw receptacle. In another embodiment one of the connectors can form a snap-fit connector and the other connector can form a snap-fit receptacle. In another embodiment one of the connectors can comprise at least one projection that is configured to fit within at least one matching space or receptacle in the other connector. In another embodiment the battery connector 207 and the aerosol section distal connector can form a friction fit.
The heater 211 can comprise a metal coil in liquid contact with the aerosol forming compound. In one embodiment the heater 211 can be mostly surrounded by the airflow path 212 and can be wound around a wick (not shown) that extends into the aerosol forming compound 213 and transports the aerosol forming compound 213 to the heater 211. In another embodiment, the heater 211 can comprise a metallic mesh that can extend from the airflow path 212 into the aerosol forming compound and that is sized and configured to transport the aerosol forming compound 213 across the heater 211. In yet another embodiment, the heater 211 can comprise a ceramic material. The ceramic material can extend from the airflow path 212 into the aerosol forming compound 213 and can be configured to transport the aerosol forming compound to the portion of the heater 211 within the airflow path 212. In one embodiment, the ceramic material can be porous. In one embodiment, the battery 206 in the battery section 201 can be electrically connected to the heater 211 in the aerosol section 202. The electrical connection between the battery 206 and the heater 211 can comprise at least one wire connecting the battery to the heater 211. In another embodiment, the electrical connection between the battery 206 and the heater 211 can comprise electrical traces disposed within or on the battery section 201 and the aerosol forming section 213. In yet another embodiment, the electrical connection between the battery 206 and the heater 211 can comprise a combination of electrical wires and electrical traces.
The airflow path 212 can be configured to draw air from outside the electronic cigarette 200 at a place distal to the heater 211 and to direct the air drawn into the electronic cigarette 200 across the heater and towards the flavorant section 203. In one embodiment, the airflow path 212 can comprise a tubular, non-porous, insoluble material that extends the length of the aerosol section 202. In an embodiment where the airflow path 212 is nonporous and insoluble, the airflow path 212 can be used keep the aerosol forming compound from the interior of the airflow path 212. The aerosol section proximal connector 215 can be configured to connect to the flavorant section 203.
The flavorant section can comprise a third housing 221, a flavorant 220, a flavorant section connector 217, and a mouth piece 222. The third housing 221 can surround the flavorant 220 and can be coupled to the flavorant section connector 217. The flavorant section connector 217 can be sized and configured to connect to the aerosol section proximal connector 215. In one embodiment one of the connectors can form a screw thread and the other connector can form a screw receptacle. In another embodiment one of the connectors can form a snap-fit connector and the other connector can form a snap-fit receptacle. In another embodiment one of the connectors can comprise at least one projection that is configured to fit within at least one matching space or receptacle in the other connector. In another embodiment the flavorant section connector 217 and the aerosol section proximal connector can form a friction fit.
The flavorant 220 can comprise materials as will be described later in this disclosure. The flavorant 220 can be configured to transfer a flavor or other substance to an aerosol that passes through the flavorant section 203. In one embodiment, the flavorant 220 can comprise a flavor and nicotine. In other embodiments the flavorant can only comprise a flavor. In yet another embodiment, the flavorant can comprise only nicotine. The mouth piece 222 can be configured to fit within a distal end of the first housing 205 and in at least one embodiment can comprise a plastic material
In one embodiment, the aerosol section proximal connector can further be configured to receive a separator 216. The separator 216 can be sized and configured to fit within the aerosol section proximal connector 215 of the aerosol section 202 and can separate the aerosol forming compound 213 from a flavorant 220 of the flavorant section 203. In another embodiment, the separator 216 can be sized and configured to fit within the flavorant section connector 217 of the flavorant section 203 and can separate the aerosol forming compound 213 from a flavorant 220 of the flavorant section 203.
In one embodiment, the electronic cigarette 300 of
The embodiment of the insert section 420 depicted in
Furthermore, the flavor containing inserts of this disclosure can be packaged as pressure releasable blisters, peelable ribbons or similar package strategies known in the packaging industry. One example of a package is shown in
Although several embodiments have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit of the present disclosure. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the present teachings. The foregoing description and following claims are intended to cover all such modifications and variations. Further, although only certain embodiments of this invention have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention.
Various embodiments are described herein of various apparatuses, systems, and methods. Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments as described in the specification and illustrated in the accompanying drawings. It will be understood by those skilled in the art, however, that the embodiments may be practiced without such specific details. In other instances, well-known operations, components, and elements have not been described in detail so as not to obscure the embodiments described in the specification. Those of ordinary skill in the art will understand that the embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the scope of the embodiments, the scope of which is defined solely by the appended claims.
Furthermore, the flavor containing inserts of this invention can be packaged as pressure releasable blisters, peelable ribbons or similar package strategies known in the packaging industry. An example is shown in
Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” “an embodiment,” or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” “in an embodiment,” or the like, in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features structures, or characteristics of one or more other embodiments without limitation.
It will be appreciated that the terms “proximal” and “distal” may be used throughout the specification with reference to a clinician manipulating one end of an instrument used to treat a patient. The term “proximal” refers to the portion of the instrument closest to the clinician and the term “distal” refers to the portion located furthest from the clinician. It will be further appreciated that for conciseness and clarity, spatial terms such as “vertical,” “horizontal,” “up,” and “down” may be used herein with respect to the illustrated embodiments. However, surgical instruments may be used in many orientations and positions, and these terms are not intended to be limiting and absolute.
Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated materials does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.
This application claims the benefit of priority to U.S. provisional application No. 62/081,870, filed 19 Nov. 2014, which is hereby incorporated by reference as though fully set forth herein.
Number | Date | Country | |
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62081870 | Nov 2014 | US |