BR112020008622A2 - aerosol generating article, assembly, system, process for making an article and method for preventing a user from igniting or burning an aerosolizable material - Google Patents

Abstract

AEROSOL GENERATOR ARTICLE, SET, SYSTEM, PROCESS FOR MANUFACTURING AN ARTICLE AND METHOD FOR PREVENTING THAT A USER CAUSES IGNITION OR BURNS AEROSOLIZABLE MATERIAL. An aerosol generating article (101) is described here, the article comprising an aerosolizable material (103) and an aerosolized material packaging (102) arranged around the aerosolizable material, in which the packaging material comprises a non-combustible material and the packaging material extends from a first end of the aerosolizable material and over about 10% to about 85% of the distance to a second end of the aerosolizable material. Accompanied by Figure 1

Description

AEROSOL GENERATOR ARTICLE, SET, SYSTEM, PROCESS FOR MANUFACTURE AN ARTICLE AND METHOD TO PREVENT A USER TO CAUSE

IGNITION OR BURN AEROSOLIZABLE MATERIAL Technical Field

[0001] The present invention relates to smoking articles and, specifically, although not exclusively, to an aerosol generating article, the aerosol generating article comprising a wrapped aerosolizable material, and an aerosol generating assembly containing a generating article aerosol dispenser, the aerosol generating article comprising a wrapped aerosolizable material.

Background

[0002] Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. The alternatives to these types of articles release the compounds by heating, without burning, an aerosolizable material.

[0003] It is known the apparatus that heats the aerosolizable material to volatilize at least one component of the aerosolizable material, typically to form an aerosol that can be inhaled, without burning or causing combustion of the aerosolizable material. This appliance is sometimes described as a "heat without burning" appliance or a "tobacco heating product" (THP) or a "tobacco heating device" or the like. Several different arrangements are known to volatilize at least one component of the aerosolizable material.

[0004] The material can be, for example, tobacco, other non-tobacco products or a combination, such as a combined mixture, which may or may not contain nicotine.

summary

[0005] According to a first aspect, the invention provides an aerosol-generating article, the aerosol-generating article comprising an aerosolizable material and a packaging material arranged around the aerosolizable material, and wherein the packaging material comprises a material non-combustible and the packaging material extends from a first end of the aerosolizable material and over about 10% to about 85% of the distance to a second end of the aerosolizable material.

[0006] In some cases, the packaging material circumscribes the aerosolizable material.

[0007] In some cases, the aerosolizable material comprises tobacco.

[0008] In some cases, the aerosolizable material is a rod of aerosolizable material.

[0009] In some cases, the non-combustible material comprises a sheet of metal. For example, the metal sheet may comprise aluminum.

[0010] In some cases, the packaging material extends from the first end of the aerosolizable material and over 20% to about 70% of the distance to the second end of the aerosolizable material.

[0011] In some cases, the packaging material extends from the first end of the aerosolizable material over about 40% to about 65% of the distance to the second end of the aerosolizable material.

[0012] In some cases, the packaging material extends from the first end of the aerosolizable material and over 50% to about 60% of the distance to the second end of the aerosolizable material.

[0013] In some cases, the aerosol generating article may also comprise a filter and / or a cooling element. In some cases, the cooling element can be arranged between the aerosolizable material and the filter. In some cases, the filter can be placed between the aerosolizable material and the cooling element.

[0014] According to a second aspect, the invention provides an aerosol generating set comprising a heater and an aerosol generating article according to the first aspect of the invention. In some cases, the aerosol generator set may be a tobacco heating product (also known as a non-burning heat device).

[0015] Another aspect of the invention provides a system comprising an aerosol generating device and an aerosol generating article according to the first aspect.

[0016] Another aspect of the invention provides a process for the manufacture of an aerosol-generating article comprising packaging an aerosolizable material into a packaging material, wherein the packaging material comprises a non-combustible material and the packaging material is extends from a first end of the aerosolizable material and over about 10% to about 85% of the distance to a second end of the aerosolizable material.

[0017] A further aspect of the invention provides a method for preventing a user from igniting or burning an aerosolizable material in an aerosol-generating article, the method comprising wrapping the aerosolizable material in a packaging material, wherein the packaging material comprises a non-combustible material and the packaging material extends from a first end of the aerosolizable material and over about 10% to about 85% of the distance to a second end of the aerosolizable material.

[0018] Insofar as they are compatible, the characteristics of the invention described in the context of one aspect are explicitly disclosed in combination with each other aspect.

Figures

[0019] Other features and advantages of the invention will become apparent from the following figures and description of the examples of the invention (which are given by way of example only and do not limit the scope of the claims).

[0020] Figure 1 is a schematic diagram of a side view of an aerosol generating article according to an example of the invention.

[0021] Figure 2 is a schematic diagram of a first end view of an aerosol generating article according to an example of the invention.

[0022] Figure 3 is a schematic diagram of a first end view of a different aerosol generating article according to an example of the invention.

[0023] Figure 4 is a schematic diagram of a side view of an aerosol generating article according to an example of the invention.

[0024] Figure 5 is an exploded schematic diagram of a packaging material that can be used in some examples.

[0025] Figure 6 is a schematic diagram exploded of a packaging material that can be used in some examples.

Detailed Description

[0026] Figure 1 is a schematic illustration of an example aerosol generating article. The aerosol-generating article 101 includes an aerosolizable material 103 which is surrounded by a non-combustible material 102 from a first end of the aerosolizable material. In this example, the non-combustible material 102 extends approximately 50% of the distance to the second end of the aerosolizable material.

[0027] In some cases, the wrap can extend from the first end of the aerosolizable material over about 10%, 20%, 30%, 40% or 50% of the distance to the second end of the aerosolizable material.

[0028] A consideration when preparing aerosol-generating articles (such as tobacco heating products) is that they should not produce an acceptable smoking experience if the aerosolizable material is burned, so that the user does not worry about burning the aerosolizable material. This is due to the fact that the aerosolizable material formulation is not configured for combustion (and the aerosol that results from combustion may be less suitable for inhalation than the aerosol that results from heating but without burning the aerosolizable material, or aerosol resulting from the combustion of traditional cigarettes).

[0029] In use, the second end of the aerosolizable material is the end of the mouth and the first end is the distal end. (Consequently, the second end can be referred to here alternatively as the mouth end and the first end can be referred to here as the distal end). Wrapping the distal end of the aerosolizable material (i.e., the end that a user might attempt to ignite) in a non-combustible material prevents the aerosolizable material in the aerosol-generating article from being burned and smoked like a conventional combustible cigarette. The inventors have demonstrated that the propensity to burn decreases as the proportion of aerosolizable material that is involved in a non-combustible material increases.

[0030] In some examples, non-combustible packaging material may be arranged around the circumference of the tobacco material. Optionally, the non-combustible packaging material can also be arranged on the first end of the aerosolizable material, so that the first end is completely enveloped in the packaging material. Figure 2 illustrates an example in which the non-combustible material 102 is wrapped around the circumference of the aerosolizable material. The first end of the aerosol generating article 101 is not covered by the non-combustible material. Figure 3 illustrates an alternative example of an aerosol generating article 101, in which the non-combustible material 102 completely surrounds the first end of the aerosol generating article.

[0031] As used in this document, the phrase "non-combustible" refers to a material that does not ignite or burn at temperatures normally associated with the ignition or burning of tobacco.

[0032] In some cases, the casing extends from the first end of the aerosolizable material over about 85%, 80%, 75%, 70%, 65% or 60% of the distance to the second end of the aerosolizable material .

[0033] Non-combustible materials can be more expensive than traditional tobacco packaging materials, such as paper. Therefore, it can be beneficial to use as little as possible, while balancing with the need for a low propensity to burn.

[0034] In addition, non-combustible materials are typically more difficult to use in manufacturing than traditional tobacco packaging materials such as paper. For example, the inventors demonstrated that non-combustible materials can be more difficult to cut than paper; this can influence the method of making the aerosolizable material, where (a) lengths of aerosolizable materials can be cut from a longer body and (b) ventilation holes are provided in the packaging material.

[0035] The inventors have demonstrated that wrapping 10 to 85% of the length of the aerosolizable material, the wrapper extending from the first end, satisfies these various competing requirements.

[0036] In some cases, the packaging material can extend from the first end of the aerosolizable material and more than 20-70%, 40-65% or 50-60% of the distance to the second end of the aerosolizable material.

[0037] Examples of the aerosol generating article may additionally further comprise a filter and / or a cooling element. In some cases, these additional components are circumscribed by a paper wrapper which also circumscribes the aerosolizable material. In such cases, a portion of the aerosolizable material is wrapped in a paper wrapper, in addition to the wrapping material that comprises a non-combustible material, and the paper wrapper may overlap or be underlying the wrapping material that comprises a non-combustible material .

[0038] For example, the second end (i.e., the mouth end) of the aerosolizable material can be supplied adjacent to a cooling element and / or a filter. A cooling element, if present, allows the vapor components to condense to form an aerosol and / or space the very hot parts of the user's device. A filter, if present, can remove components from the fluid flow, affecting the chemical composition of the inhaled aerosol.

[0039] Figure 4 illustrates an example of an aerosol generating article 101 that includes, in addition to the characteristics of figure 1, a cooling element 104, a filter 105 and a mouth end tube 106. Cooling element 104 and the filter 105, as illustrated, can be arranged between the mouth end of the aerosolizable material 103 and the mouth end tube 106, so that the flow of the aerosolizable material 103 passes through the cooling element 104 and the filter 105 (or vice versa if the filter is placed before the cooling element in the flow) before reaching the user. Although the example in Figure 4 illustrates a cooling element 104, a filter 105 and a mouth end tube 106, one or more of these elements can be omitted in other examples.

[0040] In some examples, the mouth end tube, if present, 106 may be formed of, for example, paper, for example, in the form of a spiral-wound paper tube, cellulose acetate, cardboard, paper crimped, such as heat resistant crimped paper or crimped parchment paper, and / or polymeric materials, such as low density polyethylene (LDPE) or some other suitable material. The mouth end tube 106 can be a hollow tube. Such a hollow tube can provide a filtering function to filter the volatilized aerosolizable material. The mouth end tube 106 can be elongated so as to be removed from the very hot part (s) of the main apparatus (not shown) which heats the aerosolizable material.

[0041] In some examples, filter 105, if present, can be a filter plug and can be made, for example, from cellulose acetate.

[0042] In some cases, the cooling element 104, if present, may comprise a monolithic rod having first and second ends and comprising multiple through holes extending between the first and second ends. The through holes can extend substantially parallel to the central longitudinal axis of the stem. The through holes of the cooling element 104 can generally be arranged radially of the element when viewed in lateral cross section. That is, in one example, the element has internal walls that define the through holes and that have two main configurations, namely, radial and central walls. The radial walls extend along the radii of the element's cross section and the central walls are centered in the center of the element's cross section. The central walls in one example are circular, although other forms of regular or irregular cross-section can be used. Likewise, the cross section of the element in an example is circular, although other forms of regular or irregular cross section can be used.

[0043] In one example, most through-holes have a hexagonal or generally hexagonal cross-sectional shape. In this example, the element has what can be called a "honeycomb" structure when viewed from one end.

[0044] In some cases, the cooling element 104 may comprise a hollow tube that spans the filter 105, if present, of the very hot part (s) of the main apparatus that heats the aerosolizable material. The cooling element 104 can be formed, for example, of paper, for example, in the form of a spiral-wound paper tube, cellulose acetate, cardboard, folded paper, such as folded heat-resistant paper or folded parchment paper, and polymeric materials, such as low density polyethylene (LDPE) or some other suitable material.

[0045] Cooling element 104, if present, can be substantially incompressible. It can be formed from a ceramic material or a polymer, for example, a thermoplastic polymer, which can be an extrudable plastic material. In one example, the porosity of the element is in the range of 60% to 75%. Porosity, in this sense, can be a measure of the percentage of the lateral cross-sectional area of the element occupied by the through-holes. In one example, the porosity of the element is 69 to 70%.

[0046] Other examples of aerosol cooling elements are disclosed in PCT / GB2015 / 051253, the entirety of which is expressly incorporated by reference, in particular in Figures 1 to 8 and in the descriptive report on page 8, line 11 to page 18, line 16.

[0047] In other examples, the cooling element 104 can be formed from a sheet material which is folded, pressed or pleated to form holes. The sheet material can be made, for example, from metal such as aluminum; polymeric plastic material, such as polyethylene, polypropylene, polyethylene terephthalate or polyvinyl chloride; or paper.

[0048] In some examples, the cooling element 104 and the filter 105 can be held together by packaging paper to form a set. The assembly can then be joined to the aerosolizable material by another wrapper that circumscribes the assembly and at least the mouth end of the aerosolizable material to form the aerosol generating article 101. In other examples, the aerosol generating article 101 is formed by wrapping the cooling element 104, the filter 105 and the aerosolizable material 103 effectively in one operation, without separate tip paper being provided for the cooling element and / or filter components (if present).

[0049] In some cases, one or more ventilation openings may be formed in the article. Ventilation openings can provide air flow to the article during use that forms part of the inhaled aerosol. It may be desirable to reduce the flow of air over the distal end of the aerosolizable material to reduce the propensity to burn, and thus the openings can be formed closer to the mouth end than to the distal end. For example, ventilation holes can be formed in the cooling element and / or filter, if any. In addition, ventilation holes can be formed in a part of the article that is not involved in the non-combustible material. The inventors have demonstrated that cutting non-combustible material to form ventilation openings may not be simple.

[0050] The aerosolizable material can be a rod of aerosolizable material. As used herein, the term "rod" generally refers to an elongated body that can have any shape suitable for use in an aerosol generator set. In some cases, the stem is substantially cylindrical.

[0051] In some cases, the aerosolizable material comprises tobacco. Tobacco can be any suitable solid tobacco, such as grades or simple mixtures, cut rags or whole leaves, ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem and / or reconstituted tobacco. Tobacco can be of any type, including, without limitation, Virginia and / or Burley and / or Oriental tobacco.

[0052] In use, in some cases, the aerosol generating article can be arranged at least partially within a heating device to form an aerosol generating set, which heats the article to generate an aerosol without burning. In some other cases, the article may be supplied in conjunction with a fuel source, such as a burnable fuel source or a chemical heat source, which heats but does not burn aerosolizable material.

Packaging materials comprising a non-combustible material

[0053] In some cases, the non-combustible material comprises a sheet of metal. In some cases, it may consist essentially of or consist of a sheet of metal. Suitably, the metal sheet may comprise, essentially consist of or consist of an aluminum sheet. The metal sheet is a non-combustible material which, however, can act to conduct heat to the aerosolizable material in use.

[0054] In some cases, the metal sheet may be less than about 100 µm, 50 µm, 20 µm, 10 µm or 8 µm thick. In some cases, it can be more than about 1 µm, 3 µm or 5 µm thick.

[0055] In some cases, the aerosolizable material can be wrapped in more than one packaging material. That is, in addition to the packaging material comprising a non-aerosolizable material, the aerosolizable material can be wrapped in one or more additional materials. Such one or more other packaging materials may cover more or less aerosolizable material than the packaging material comprising a non-combustible material.

[0056] In some cases, the one or more additional packaging materials may circumscribe other components of the aerosol-generating article (in addition to the packaging material) as noted above.

[0057] In some cases, one or more additional packaging materials may comprise paper that can overlap and / or be underlying the non-combustible packaging material.

[0058] In some cases, the packaging material comprising a non-combustible material may be a laminated material. In some cases, the laminated material may comprise 2, 3, 4 or more layers.

[0059] Suitable laminated materials may comprise a layer of paper and a layer of metal foil (such as a layer of aluminum foil). In some cases, the laminated material may consist of two layers, such as a layer of paper and a layer of sheet metal.

[0060] As used here, the term "laminated structure" refers to a multilayered structure in which the layers are fastened together to form a single body. The layers can be attached with an adhesive, for example. In other examples, the layers can be attached by static interaction. In other examples, the laminated structure can be formed by (partially) melting a first layer, contacting the first layer with a second layer and allowing the first layer to solidify. Any suitable mechanism for securing the layers together, including, but not limited to, the above examples, tying, sewing, screwing, nailing, fastening, hooking, etc. can be used to form the laminated structure.

[0061] In some cases, an adhesive can coat the surface of each layer. In other cases, an adhesive can be applied only at the periphery of the layers. In some cases, each layer in the laminated structure can be attached to the adjacent layer (s). In some examples of laminated structures, the periphery of two layers can be attached together with the intermediate layers stuck in the middle.

[0062] In some cases, the laminated packaging material may comprise an inner layer comprising a sheet of metal and an outer layer comprising paper. Figure 6 illustrates this example. The laminated structure (indicated by dashed lines) is an inner layer 502 and an outer layer 501. In some cases, the laminated packaging material may consist of these two layers.

[0063] In some cases, the laminated packaging material may comprise the innermost and outermost layers that comprise paper and an intermediate layer of metal foil. Figure 5 illustrates this example. The laminated structure (indicated by dashed lines) includes the peripheral layers 501, 503 and the intermediate layer 502. In some cases, the laminated packaging material may consist of these three layers.

[0064] The packaging of the aerosolizable material in a layer of metal foil and a layer of paper, suitably a laminated wrapper as described above, provides the desired non-combustibility. In addition, the porosity of such packaging is low, which limits the lateral flow of air to the tobacco, further reducing the propensity to burn.

[0065] Furthermore, the inventors have demonstrated that having an outer layer that comprises paper (and, in some cases, also having an inner layer that comprises paper) can be beneficial, since the laminated surface (s) ), so it has a friction coefficient for that role This means that the laminated wrapper can be more easily used in known cigarette making processes and machines. Laminated surfaces with a friction coefficient equivalent to that of cigarette paper allow the garment belt of an aerosol generating article machine to guide the laminated wrapper through the garment during the aerosol generating article manufacturing process.

[0066] The inventors have further demonstrated that having paper in the innermost layer can be beneficial because it can act as a flavor carrier. That is, in some cases, the innermost layer of the laminated packaging material comprises paper and a flavoring agent which is transferred to the aerosolizable material when it is wrapped around the aerosolizable and heated material. In some cases, flavoring is impregnated in the paper in the innermost layer. In some cases, the flavoring agent may comprise menthol.

[0067] The paper in the laminated packaging materials described herein can have a basis weight of at least about 10 gm-2, 15 gm-2, 20 gm-2 or 25 gm-2 at about 50 gm-2, 45 gm-2, 40 gm-2 or 35 gm-2. Paper having a density in this range has a low porosity, which further reduces the propensity to burn by limiting the oxygen levels in the aerosolizable material.

[0068] The paper can be treated with one or more burning retardant substances.

[0069] The laminated material can be wrapped around the core of the coil for use with standard cigarette makers that are fed from a single paper coil.

[0070] The laminated material can be formed using any suitable lamination technique. In one example, the layers can be adhered together.

[0071] The above examples are to be understood as illustrative examples of the invention. It is to be understood that any feature described in relation to any example can be used alone or in combination with other features described and can also be used in combination with one or more features of any other example, or any combination of any other of the examples.

In addition, equivalents and modifications not described above can also be employed without departing from the scope of the invention, which is defined in the appended claims.

Claims (17)

1. Aerosol-generating article, characterized by the fact that it comprises an aerosolizable material and a packaging material arranged around the aerosolizable material, in which the packaging material comprises a non-combustible material and the packaging material extends from a first end of the aerosolizable material and over about 10% to about 85% of the distance to a second end of the aerosolizable material. 2. Aerosol-generating article according to claim 1, characterized by the fact that the packaging material circumscribes the aerosolizable material. Aerosol-generating article according to claim 1 or claim 2, characterized in that the aerosolizable material comprises tobacco. Aerosol-generating article according to any one of claims 1 to 3, characterized in that the aerosolizable material is a rod of aerosolizable material. Aerosol-generating article according to any one of claims 1 to 4, characterized in that the non-combustible material comprises a sheet of metal. An aerosol-generating article according to claim 5, characterized in that the metal sheet comprises aluminum. Aerosol-generating article according to any one of claims 1 to 6, characterized in that the packaging material extends from the first end of the aerosolizable material and over about 20% to about 70% of the distance to the second end of the aerosolizable material. Aerosol-generating article according to any one of claims 1 to 7, characterized in that the packaging material extends from the first end of the aerosolizable material and over about 40% to about 65% of the distance to the second end of the aerosolizable material. Aerosol-generating article according to any one of claims 1 to 8, characterized in that the packaging material extends from the first end of the aerosolizable material and over about 50% to about 60% of the distance to the second end of the aerosolizable material. An aerosol-generating article according to any one of claims 1 to 9, characterized by the fact that it also consists of a filter and / or a cooling element. Aerosol-generating article according to claim 10, characterized in that the aerosol-generating article comprises a filter and a cooling element, and in which the cooling element is disposed between the aerosolizable material and the filter. 12. Aerosol generating set characterized by the fact that it comprises an aerosol generating article as defined in any one of claims 1 to 11. Aerosol generating set according to claim 12, characterized in that the set is a tobacco heating product. Aerosol generating set according to claim 12 or claim 13, characterized in that the heater is a device in which the aerosol generating article is at least partially inserted in use. 15. System characterized by the fact that it comprises an aerosol generating device and an aerosol generating article as defined in any one of claims 1 to 11. 16. Process for manufacturing an aerosol-generating article, characterized by the fact that it comprises wrapping an aerosolizable material in a packaging material, in which the packaging material comprises a non-combustible material and the packaging material extends from a first end of the aerosolizable material and over about 10% to about 85% of the distance to a second end of the aerosolizable material. 17. Method to prevent a user from igniting or burning an aerosolizable material in an aerosol-generating article, characterized by the fact that it comprises wrapping the aerosolizable material in a packaging material, where the packaging material comprises a non-combustible material and the packaging material extends from a first end of the aerosolizable material and over about 10% to about 85% of the distance to a second end of the aerosolizable material.