Patent Application
20200068950
Heat-not-burn (HNB) products have been proposed as a non-combustible alternative to traditional cigarettes. Such products generate inhalable vapor by heating, rather than burning, tobacco and/or other tobacco constituents. The resulting aerosol, inhaled by the consumer, typically contains nicotine and other additives used to enhance user experience. Essentially, successful HNB products must release an abundance of fluid (i.e., gaseous) to provide a dose of at least nicotine and the full mouth sensation of smoking. These molecular attributes are carried in the fluid, rather than in the tobacco particulates of combustible cigarettes.
In order to gain mass-market appeal as a smoking replacement, HNB products try to replicate, and/or best approximate, the sensation of smoking conventional cigarettes. It would, therefore, be desirable to provide a non-combustible smoking article that allows consumers to customize their smoking experience in much of the same way as conventional cigarette options allow.
Various methods for modifying the sensory attributes of conventional cigarettes are known in the art. For example, specialized cigarette filters are known to incorporate a variety of elements, such as flavor-releasing capsules, in order to modify the characteristics of the mainstream smoke that passes through those filter elements. These elements may be used for a variety of purposes, such as imparting flavor or reducing some chemical elements from the cigarette smoke to be inhaled by the consumer. Accordingly, it would be desirable to provide a non-combustible smoking article that allows different sensory experiences at the discretion of the consumer.
According to an exemplary embodiment, a non-combustible smoking article may be described herein. The non-combustible smoking article may include a composite filter forming an elongated, cylindrical rod. The composite filter may further include a cavity having a nicotine source; an aerosol-forming substrate proximate the nicotine source; and at least one capsule filled with an additive for modifying a characteristic of inhalable vapor. An internal heater may be inserted into at least the cavity having the nicotine source of the composite filter. A peripheral heating source may also be disposed along an external length of the composite filter.
According to another exemplary embodiment, a method of using a non-combustible smoking article may be provided herein. The method may include providing a non-combustible smoking article having a composite filter, the composite filter further comprising: a cavity having a nicotine source; an aerosol-forming substrate proximate the nicotine source; and at least one capsule filled with an additive for modifying a characteristic of inhalable vapor. The method may further include the steps of: inserting an internal heater into at least the cavity having the nicotine source of the composite filter; applying a peripheral heating source to a length of the composite filter; and activating the internal heater and the peripheral heating source to heat at least a portion of the composite filter, wherein the heat generates the inhalable vapor to be drawn and inhaled by a consumer.
Advantages of embodiments of the present invention will be apparent from the following detailed description of the exemplary embodiments. The following detailed description should be considered in conjunction with the accompanying figures in which:
Aspects of the present invention are disclosed in the following description and related figures directed to specific embodiments of the invention. Those skilled in the art will recognize that alternate embodiments may be devised without departing from the spirit or the scope of the claims. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention. Further, to facilitate an understanding of the description discussion of several terms used herein follows.
As used herein, the word “exemplary” means “serving as an example, instance or illustration.” The embodiments described herein are not limiting, but rather are exemplary only. It should be understood that the described embodiments are not necessarily to be construed as preferred or advantageous over other embodiments. Moreover, the terms “embodiments of the invention,” “embodiments,” or “invention” do not require that all embodiments of the invention include the discussed feature, advantage, or mode of operation.
According to an exemplary embodiment, a non-combustible smoking article may be described herein. The non-combustible smoking article may include a composite filter. The composite filter may further include a cavity having a nicotine source; an aerosol-forming substrate proximate the nicotine source; and at least one capsule filled with an additive for modifying a characteristic of inhalable vapor. An internal heater may be inserted into the non-combustible smoking article, piercing and extending through at least the nicotine-containing cavity of the composite filter. A peripheral heating source may also be applied to an exterior of the smoking article, along a length of the composite filter. Both heating components (i.e., internal heater and peripheral heating source) may be activated to warm the composite filter, ensuring a more uniform heat distribution profile across the smoking article. The heating, not burning, of the product generates an inhalable vapor, which is drawn through the smoking article and condensed into an aerosol to be inhaled by the consumer. The composite filter may differ in size, shape, and/or construction to impart a customizable smoking experience.
Referring now to the figures,
The composite filter 100 may generally form an elongate, cylindrical rod 102, which can be partitioned into a number of different segments. Each segment may have a specific purpose, and/or one or more substances disposed therein. In some exemplary embodiments, for example, the composite filter 100 may include a filter stopper 104, a cavity 106 having a nicotine source 108, an aerosol-forming substrate 110 proximate the nicotine source 108, and at least one capsule 112 filled with an additive for modifying a characteristic of inhalable vapor.
The composite filter 100 may be constructed from a base filter material, such as cellulose, cellulose acetate tow, paper, cotton, polypropylene web, polypropylene tow, polyester web, polyester tow, or any combination thereof. The base filter material may be enclosed in a wrapper 114. The wrapper 114 may circumscribe the entire length of the filter 100. The wrapper 114 may be formed from a paper stock tube. The paper stock tube may be made, for instance, from flax, linen fiber, or any other suitable material known in the art. The paper stock tube may allow zero pressure differential and removals, whilst producing a longer (and more balanced looking) product. In some exemplary embodiments, the paper tube may also allow the composite filter to be combined with a thinner, more porous plug wrap.
The tight retention and integrity of all segments into the product may be ensured by multiple anchor lines applied to the inside of the wrapper. The anchorage adhesive may be, for example, a hot melt adhesive or an emulsion-based (e.g., EVA, PVA or PVOH) adhesive. The number of lines and the ration of adhesive may depend on the application and can vary according to the needs and design.
In some exemplary embodiments, a non-combustible segment may be provided at either end of the composite filter 100. The non-combustible segment may be constructed from cellulose acetate or other non-burning material known in the art. In some exemplary embodiments, for example, the non-combustible segment may be made from polylactic acid (PLA) material or ceramic segments. The non-combustible segment may form a filter stopper 104 that is attached to an end portion of the composite filter 100. The filter stopper 104 may be approximately 2 mm in diameter, thereby allowing easier penetration of an internal heating probe, and/or consecutive cleaning of said probe once removed from the filter body.
As shown in
In some exemplary embodiments, the tobacco material 108 may be formed by grinding or otherwise comminuting parts of the tobacco plant (e.g., leaf lamina, stem, etc.). In some exemplary embodiments, the tobacco material 108 may be composed of one or more of the following: tobacco dust, tobacco powder, tobacco fines, reconstituted tobacco sheet, cast leaf, and other tobacco particulates formed during, for example, the tobacco processing operation.
The tobacco material 108 may be treated with an aerosol-forming substrate 110, for example glycerin and/or propylene glycol. The aerosol-forming substrate 110 may be introduced into the cavity 106 by a spraying means, such as a spray nozzle, atomization apparatus, injection nozzle, gravity-actuated nozzle, pressure and/or gravity-actuated applying apparatus, or any other suitable device as would be understood by one of ordinary skill in the art. The aerosol-forming substrate 110 may be applied via the spraying means before, and/or during, and/or after the insertion of the tobacco material 108 into the cavity 106.
In some exemplary embodiments, and as shown in
The aerosol-forming capsule may include a shell having an aerosol-forming substance 110 therein. The shell may be formed from a variety of materials, so as to conform to desired physical properties for shell. In some exemplary embodiments, for example, the shell may be formed from a water-soluble material, and may thus dissolve upon contact with water or exposure to a desired amount of humidity. In other exemplary embodiments, the shell may be made from a gelatinous material. In some exemplary embodiments, the shell may be frangible upon application of sufficient pressure. Thus, if pressure is applied to a capsule, for example by squeezing, the capsule may rupture, thereby releasing the substance therein. The pressure required to rupture shell may be varied to meet desired specifications.
In some exemplary embodiments, the aerosol-forming capsule may be disposed substantially coaxial to the longitudinal axis of the composite filter 100. The aerosol-forming capsule may be inserted into the composite filter 100 by on-line or in-line addition. Any known insertion technique may be employed, such as those described in U.S. Pat. No. 8,622,882, and U.S. Pat. No. 8,303,474, which are incorporated herein by reference in their entirety. In some exemplary embodiments, the aerosol-forming substrate (e.g., glycerin and/or propylene glycol) and/or nicotine may be introduced into the cavity 106 by any of the spraying means described herein.
The nicotine-carrying cavity 106 may be formed using wrapping material as further described below. An endless plug wrap paper with different type segments in length may be formed, thus creating a cavity therebetween. When the plug wrap paper is overlapped, a cavity may form between segments. The cavity dimensions may be as follows: the diameter may vary between 4.5-12 mm, the height may vary between 4-67 mm. This may be accomplished using forced feeding, plunger, pusher, suction, and/or blowing technologies. Both gravity and forced feeding into the cavity may be available, and can be using according to the need of application. For example, the technology may include gravity-actuated cavity filling stations with predetermined amounts of material. In one exemplary embodiment, for example, the volume of the nicotine-carrying cavity 106 may range from approximately 63 to 7578 mm3. The filling rate of the cavity 106 can vary depending on consumer preference. For example, the filling rate (i.e., tobacco volume to cavity volume ratio) of the cavity 106 may range from approximately 5% to 95% full.
The shell 116 may be formed from a variety of materials, so as to conform to desired physical properties for shell 116. In some exemplary embodiments, for example, the shell 116 may be formed from a water-soluble material, and may thus dissolve upon contact with water or exposure to a desired amount of humidity. In other exemplary embodiments, the shell 116 may be made from a gelatinous material. In some exemplary embodiments, the shell 116 may be frangible upon application of sufficient pressure. Thus, if pressure is applied to a capsule 112, for example by squeezing, the capsule 112 may rupture, thereby releasing the additive therein. The pressure required to rupture shell 116 may be varied to meet desired specifications. For example, each shell 116 may be adapted to rupture upon application of pressure by a consumer's fingers. In some exemplary embodiments, the shell 116 may rupture when a force of between approximately 19 newton (N) and approximately 11 N is applied thereto. Alternatively, the shell 116 may be air permeable so that it does not need to be ruptured in order to efficiently utilize the additive therein. For example, the shell 116 may be microporous.
As shown in
The heat-initiating capsule 300 may form a multi-compartment (e.g., capsule-in-capsule) structure having at least two segregated chemical reactants. As illustrated in
Each capsule shell 306, 308, 312 may be formed from a variety of materials, so as to conform to desired physical properties for that respective capsule. In some exemplary embodiments, for example, one or more shells may be formed from a water-soluble material, and may thus dissolve upon contact with water or exposure to a desired amount of humidity. In other exemplary embodiments, one or more shells may be made from a gelatinous material. In some exemplary embodiments, one or more shells may be frangible upon application of sufficient pressure. Thus, if pressure is applied to capsule 300, for example by squeezing via a consumer's fingers, one or more shells 306, 308, 312 may rupture, thereby releasing the chemicals reactants 310, 314 from therewithin.
Each capsule 300, 302, 304 may be present in various shapes, sizes, and/or configurations. The shape of any one capsule may, for example, be substantially ellipsoidal, spherical, cylindrical, rectangular, irregular, or as otherwise needed for an intended application. It should be appreciated that size limitations may exist based on the available space within the composite filter. Additionally, the chemicals reactants 310, 314 may be present in any form (i.e., gaseous, liquid, solid, or any combination thereof) and composed of any desired element, compound, or mixture capable of triggering an exothermic response upon initiating contact and/or suitable activation. In one exemplary embodiment, for example, the chemical reactants 310, 314 may include a metal and a strong oxidizing agent. It should be contemplated, however, that a variety of reactants may be substituted to produce an exothermic reaction with desired specifications (e.g., rate of reaction, temperature, etc.) as would be understood by one of ordinary skill in the art.
One or more heating sources may also interact with the filter 402. For example, an internal heater 412 may be inserted into at least the cavity 404 having the nicotine source 406 of the composite filter 400. In some exemplary embodiments, the internal heater 412 may also rupture a capsule filled with an aerosol-forming substrate 408. The internal heater 412 may take any suitable form, including a heating blade, heating plate, electrically-powered linear heating element, and the like. The cross-sectional shape of the internal heater 412 may take various forms, including but not limited to: cylindrical, triangular, rectangular, conical, elliptical, and pyramidal.
A peripheral heating source 414 may also be disposed along an external length of the composite filter 400. The peripheral heating source 414 may take any suitable form known in the art. Both heating components 412, 414 can be activated to warm the composite filter 402, ensuring a more uniform heat distribution profile across the smoking article.
The heating, not burning, of the product generates an inhalable vapor, which is drawn through the smoking article and condensed into an aerosol to be inhaled by the consumer. The heat applied to the composite filter 402 can have different profiles along the length thereof, and/or different temperatures at different time(s) depending on a predetermined variable, such as the number of puffs by a consumer. The peripheral heating source 414, for example, may include a plurality of heating regions that operate independently from one another so that different regions can activate at different times. In some exemplary embodiments, heat may not be applied at the filter stopper, or at any other non-combustible segment. These heating characteristics may allow for simultaneous and/or differentiated release of nicotine and/or the aerosol-forming substrate and/or the vapor additive.
Each heater 412, 414 may be provided as part of the non-combustible smoking article 400. The temperature of the internal heater 412 and/or the peripheral heating source 414 may differentiate between 90° F. and 350° F., and vary over time. The internal heater 412 and peripheral heating source 414 may be made of various materials, such as different types of steel, ceramic, graphite, carbon, nichrome, Kanthal®, cupronickel, platinum, and gold. The heating temperatures may be preprogrammed or controllable by the consumer.
The foregoing description and accompanying figures illustrate the principles, preferred embodiments, and modes of operation of the invention. However, the invention should not be construed as being limited to the particular embodiments discussed above. Additional variations of the embodiments discussed above will be appreciated by those skilled in the art.
Therefore, the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments may be made by those skilled in the art without departing from the scope of the invention as defined by the following claims.
