JP2021530995A - Articles for forming aerosols - Google Patents

Abstract

Article for Forming an Aerosol An article (1) for forming an aerosol, wherein the article (1) has a cover layer (20) having a peripheral mold surface (20) surrounding a molded aerosol-forming substrate (3). 2) is provided. The article (1) can be inserted into the heating chamber of the device for generating the aerosol during use. A method for manufacturing the article (1) is also provided. [Selection diagram] Fig. 1

Description

The present invention generally relates to an article for forming an aerosol and a method for producing the same.

So far, in the art, an apparatus for heating an aerosol-forming substrate instead of burning it to generate an aerosol has been proposed. For example, heated smoking devices have been proposed in which tobacco is heated rather than burned. One purpose of such heat-not-burn smoking articles is to reduce the types of unwanted and harmful smoke components produced by tobacco burning and pyrolysis in conventional cigarettes. These heated smoking devices are commonly known as "heated non-combustion" devices.

The above-mentioned types of heated smoking devices generally include a heating chamber provided with a heated surface (eg, defined by a heated surface), in which an article for forming an aerosol before use. Is inserted. Articles for forming aerosols typically contain an aerosol-forming substrate, which is later heated by the heater of the device to generate an aerosol. Thus, when the aerosol-forming substrate contained in the article is depleted, the article can be replaced, thus the heated smoking device is a reusable device, while the article is a "consumable" product. including. Articles for forming aerosols are usually shaped and sized to mimic traditional cigarettes. Thus, the article and the heating chamber in which the article is inserted or inserted into the heated smoking device generally have a cylindrical shape. Typically, the diameter of the article is 5-10 mm, for example about 7.2 mm.

Articles for forming the above-mentioned types of aerosols typically have a wrapper or carrier layer in which the aerosol-forming substrate and other component components are held. The aerosol-forming substrate may have the form of a sheet or leaf tobacco and may be crimped and / or rolled into, for example, a plug shape. Aerosol-forming substrates are typically formed in the desired shape (eg, plug shape) and combined with other component parts of the article for forming the aerosol, followed by a wrapper or carrier layer wrapped around it. Other component parts of the article may include filter material, which can be provided on one or both edges of the article, to hold the aerosol-forming substrate in the article, and also to heat during use. Acts as a plug to filter the aerosol generated by the smoking device. In addition, an aerosol cooling element, which may be formed, for example, from an aggregate of sheets of polylactic acid, may be located within the article between the aerosol-forming substrate and the filter at one end of the article. Additionally, a support element (eg, a support element formed from a hollow acetate tube) may be positioned between the aerosol-forming substrate and the aerosol cooling element.

During use, the user inserts an article between the heated surfaces of the heating chamber of the heated smoking device. The user then draws air through the free end of the article (the free end contains the filter material). A heater in a heated smoking device is activated to transfer heat energy from the heated surface to an article for forming an aerosol via one or more of conduction, convection and radiation. In this way, the volatile compounds are released from the aerosol-forming substrate. Air is drawn into the heated smoking device by the user inhaling an article to form an aerosol. Air flows through at least a portion of the device, then into the article along the length of the article, through the aerosol-forming substrate, and withdraws the volatile compounds released from the aerosol-forming substrate with the air. The mixture of airflow and volatile compounds then passes through the cooling segment, where the volatile compounds are cooled and condensed into an aerosol. The aerosol then passes through the filter material before being drawn into the user's lungs. The wrapper or carrier layer acts as a baffle during this process and guides the air flow to the user through the article.

The activation of the heater may be triggered by a smoke-absorbing sensor, for example, the smoke-absorbing sensor may react to airflow flowing beside it or flowing through it beyond a preset threshold. As is understood, using such a trigger mechanism, the user of the device begins to draw air through the device prior to heating and thus prior to the release of volatile compounds. Therefore, there is a delay between when the user begins to inhale the device and when it produces an aerosol (hence the time it takes for the generated aerosol to reach the user).

Devices for generating the types of aerosols described above are typically portable and are generally intended to be held between the fingers of one hand. Users of such devices can carry the device from place to place. For example, a user may store the device in a pocket of clothing between uses. Replacement items for forming aerosols are typically stored in packs or cases, and users must also remember to carry them. Articles that are typically cigarette-shaped (as described above) are generally stored in packs or cases that have a shape similar to a cigarette box. Packs or cases of articles for forming aerosols can also be stored in clothing pockets when the device is not in use. Storing both the device for generating aerosols and one or more packs or cases of articles for forming aerosols can be difficult, depending on the size of the user's pocket. In any case, such storage can be unsightly and / or unpleasant. In addition, when the pack or case or each of them is partially empty (as the articles used to form the aerosol are used and discarded), the remaining items move within the pack or case and the user moves around. Tends to generate unwanted noise when

Heating the aerosol-forming substrate rather than burning it requires heating the aerosol-forming substrate to a relatively low temperature. Therefore, it is necessary to transfer a relatively low amount of thermal energy to the aerosol-forming substrate. The energy saved beneficially reduces the cost of operating the heated smoking device and / or increases the useful number of actions that the device can perform before it runs out of energy reserves. However, it would be beneficial to further reduce the amount of thermal energy required to volatilize the compound from the article for forming the aerosol.

It would be desirable to provide an article for forming an aerosol that is improved over the conventional article for forming an aerosol. It would be desirable to provide articles for forming aerosols that alleviate one or more of the problems identified above. At the time of use, the aerosol is formed, which facilitates the transfer of thermal energy from the device for generating the aerosol to the aerosol-forming substrate relatively efficiently and / or faster than is achieved with conventional articles. It would be desirable to provide goods for this. It would be desirable to provide an article for forming an aerosol that requires a relatively small amount of heat energy when heated in the heating chamber of the device for generating the aerosol. Provided is an article for forming an aerosol that can be carried more easily and / or quieter by the user of the device for generating the aerosol as compared with the case of the conventional article for forming an aerosol. Would be desirable to do. It would also be desirable to provide a method of making an article for forming an aerosol, which has one or more of the advantages identified above.

According to aspects of the invention, a method or method of manufacturing an article for forming an aerosol is provided, wherein the method is:
a) A process of providing a mold surface for defining the perimeter of an article for forming an aerosol, and
b) The process of depositing a substance that is at least partially fluid and contains an aerosol-forming substrate on the mold surface.
c) The step of providing an article for forming an aerosol, comprising at least partially solidifying or enabling it, thereby having a periphery formed from the surface of the mold.

Advantageously, the mold surface provides a barrier that reduces contact between the aerosol-forming substrate and the user handling the article, for example when inserting or removing the article into or from a device for generating an aerosol. In addition, the material containing the aerosol-forming substrate is in relatively closer contact with the mold surface than in the case of contact between the aerosol-forming substrate and the cover layer or wrapper of the conventional article for forming the aerosol. Has. Therefore, heat transfer from the peripheral heating surface of the heating chamber of the apparatus for generating the aerosol to the aerosol forming substrate is relatively more efficient than in the case of conventional articles for forming the aerosol. Without wishing to be bound by any particular theory, it is believed that conventional articles for forming aerosols may include at least a partial air barrier between the wrapper and the enclosed aerosol-forming substrate. This air barrier provides an insulating layer between the aerosol-forming substrate and the heat source outside the article. In addition, heat conduction between the wrapper and the aerosol-forming substrate is limited or blocked in these conventional articles for forming aerosols. However, the articles for forming aerosols according to the present invention alleviate the above-mentioned problems due to the relatively closer contact between the mold surface and the material containing the aerosol-forming substrate, thus alleviating the above-mentioned problems and thus during use. It provides more efficient heating of the aerosol-forming substrate. Therefore, relatively low thermal energy is required to heat the aerosol-forming substrate to the required temperature and release the volatile compounds from it. Therefore, the power source of the device for generating the aerosol, in which the article for forming the aerosol is heated, is a relatively large number of times (relative to a given amount of released volatile compounds). Can be used for heating operations. Therefore, the device is more useful to the user, requires less frequent recharging (if possible) or replacement (if necessary), with associated cost savings and improved user convenience.

As used herein, the phrase "aerosol-forming substrate" is used to describe a substrate capable of releasing a volatile compound capable of forming an aerosol with heating. Aerosols generated from the aerosol-forming substrates described herein may or may not be visible to the human eye. The aerosol-forming substrate may include a solid substrate, a fluid substrate, or a mixture of solid and fluid. When the aerosol-forming substrate is fluid, the aerosol-forming substrate is advantageously retained in the matrix and / or by a cover layer, at least before being accepted into the heating chamber.

As used herein, the term "aerosol" is used to describe a suspension of relatively small particles in a fluid medium.

As used herein, the phrase "mold surface" is intended to mean a surface for molding at least a partial fluid onto the surface (eg, in step b).

As used herein, the term "periphery" is intended to mean the outer limit of the volume of an article for forming an aerosol.

In some embodiments, depositing the material on the mold surface may include pouring, injecting, or extruding the material, or otherwise flowing the material. The material can be deposited on the mold surface (eg, on the mold surface) in the first direction or in the deposition direction (eg, in a single direction). In some embodiments, in a cross section across the first direction or the deposition direction, the mold surface may surround substantially all or all around the formed article for forming the aerosol.

In some embodiments, solidifying or enabling the substance at least partially may include at least partially cooling the substance. Cooling a substance is possible, for example, when the flow of the fluid has a temperature relatively lower than that of the substance, and / or directs the flow of the fluid (eg, gas or liquid) to the substance. May include.

In some embodiments, the method may include, for example, step d) in which the material is foamed to form open cell or closed cell foam. Step d) can occur after step b) or before step b).

In some embodiments, the method may include the step e) of reticulating the foam. Step e) can occur after step b) or before step b). Reshaping the foam may include adding heat and / or one or more chemicals to the foam.

In some embodiments, the method may include the step f) of adding one or more of a flavoring agent, an aerosol-forming body and nicotine to the mold surface and / or the substance. Addition may include contacting the mold surface and / or material with one or more of flavoring agents, aerosol-forming bodies and nicotine. Contacting may include spraying, coating and / or dipping. The addition may include impregnating the mold surface and / or substance with one or more of flavoring agents, aerosol-forming bodies and nicotine. In embodiments, step f) comprises one or more of flavoring agents, aerosol-forming bodies, and nicotine, or each of them, before, after, or at the same time as step b). It may include coating or adding to the mold surface.

In some embodiments, the method also comprises the step g) of forming a frail line on the surface of the material and / or the mold, thereby at least partially defining, for example, the first and second parts of the material. good.

In some embodiments, the method may include step h) separating one or the first portion of the substance from one or the second portion of the substance, eg, using a separator. The mold surface may include a separator. For example, the mold surface may be formed integrally with the separator. Alternatively, the separator may be located in or on the mold surface.

In some embodiments, the material may comprise only an aerosol-forming substrate. Alternatively, the material may include an aerosol-forming substrate and additional material, such as a carrier material. The carrier material and / or aerosol-forming substrate may include foam (if formed). When the carrier material foams to form a foam, the aerosol-forming substrate may be provided or embedded in the foam of the carrier material or on the foam of the carrier material. The substance may include, for example, tobacco such as reconstituted tobacco (eg, petioles, etc.). The substance may include nicotine.

According to one aspect of the invention, an article for forming an aerosol is provided, the article comprising a peripheral mold surface surrounding a molded aerosol forming substrate, for the article to generate an aerosol during use. It can be inserted into the heating chamber of the device.

In some embodiments, the peripheral mold surface may surround substantially all or all of the perimeter of the article in cross section.

In some embodiments, the aerosol-forming substrate may include, for example, first and second portions at least partially defined by a fragile portion of the aerosol-forming substrate and / or the peripheral mold surface.

The article may include, for example, a cover layer that includes, defines, or can be a peripheral mold surface (eg, on its inwardly facing surface). The cover layer can be formed from a polymer such as plastic for food and / or paper such as filter paper. Additional or otherwise, the cover layer may contain any other suitable material, such as abaca fiber. The cover layer may contain cellulose. The cover layer may contain tobacco (eg, reconstituted tobacco) and / or may be formed at least partially from tobacco. The cover layer may be provided with a plurality of openings through its thickness, for example the plurality of openings may be uniformly or randomly arranged. The cover layer may include a net or mesh or fabric. Alternatively, the cover layer may include, for example, a solid surface having multiple openings-free regions (eg, major regions) through its thickness. The cover layer may provide, for example, an outer layer of the article. Alternatively, the article may include an additional layer on and / or around the cover layer. Additional layers (if provided) may include removable or temporary layers, such as layers intended to be removed prior to use of the article. The additional layer may be wrapped or otherwise secured onto and / or around the cover layer, eg, after step c) of the method of making an article for forming an aerosol.

The aerosol-forming substrate preferably contains nicotine. The aerosol-forming substrate may contain tobacco. Alternatively, or additionally, the aerosol-forming substrate may comprise a tobacco-free aerosol-forming material.

When the aerosol-forming substrate is a solid aerosol-forming substrate, the solid aerosol-forming substrate (eg, contains one or more of herbal leaves, tobacco leaves, tobacco stems, swollen tobacco and homogenized tobacco), for example. It may contain one or more of powders, granules, pellets, fragments, twisted yarns, strips or sheets.

Optionally, the solid aerosol-forming substrate may contain tobacco or non-tobacco volatile flavor compounds, which are released upon heating of the solid aerosol-forming substrate.

When the aerosol-forming substrate is in the form of a fluid, eg, a liquid or gas, the aerosol-forming substrate may contain a volatile flavor compound of tobacco or non-tobacco that is released upon heating of the fluid aerosol-forming substrate.

Optionally, the solid or fluid aerosol-forming substrate may be provided on or embedded in a carrier material (eg, a thermally stable carrier material). The carrier material can take the form of a foam, such as an open cell foam or a closed cell foam. The solid or fluid aerosol-forming substrate may be deposited over the entire carrier material, eg, over its volume. Additional or otherwise, the solid or fluid aerosol-forming substrate can be deposited on the surface of the carrier material, for example in the form of sheets, foams, gels, or slurries. The solid or fluid aerosol-forming substrate may be deposited over the entire surface of the carrier material, or otherwise may be deposited in a pattern to provide non-uniform flavor delivery during use.

In some embodiments, the aerosol-forming substrate may comprise a foam. The foam can be open cells or closed cells. The foam may be a reticulated open cell foam. The foam may be at least partially formed from tobacco, such as reconstituted tobacco (eg, stems).

Articles for forming aerosols may contain volatile flavor-generating components. Aerosol-forming substrates (and / or carrier materials, if provided) may contain volatile flavor-generating components. Volatile flavor-generating components are at least portion of the surface of the aerosol-forming substrate and / or carrier material (if provided) and / or the cover layer (if provided) and / or the surface of the surrounding mold. Can be retained and / or impregnated, and / or can be located.

As used herein, the term "volatile flavor-generating component" is arbitrary that is added to an aerosol-forming substrate (eg, and / or, if provided, a carrier material) to provide a flavoring agent. Used to describe volatile components.

Suitable flavoring agents include natural or synthetic menthol, peppermint, spearmint, coffee, tea, spices (such as cinnamon, cloves and ginger), cocoa, vanilla, fruit flavors, chocolate, eucalyptus, geranium, eugenol, ryuzetsuran, byaxin, Materials containing, but not limited to, anethole, linarool, etc.

As used herein, the term "menthol" is used to describe compound 2-isopropyl-5-methylcyclohexanol, which is one of the forms of the isomer.

Menthol may be used in solid or liquid form. In solid form, menthol may be provided as particles or granules. The term "solid menthol particles" may be used to describe any granular or particulate solid material consisting of at least approximately 80% by weight menthol.

It is preferable that 1.5 mg or more of the volatile flavor-generating component is contained in the aerosol-forming substrate.

The volatile flavor-generating component may be in liquid or solid form (if provided). The volatile flavor-generating component can be attached to or otherwise associated with the supporting element. The support element may include any suitable substrate or support for locating, maintaining, or retaining the flavor-generating component. For example, the support element can include a fibrous support element, which can be saturated with a fluid, eg, a liquid, or can be saturated.

In some embodiments, the volatile flavor-generating component may have any suitable structure in which the structural material encapsulates the flavoring agent (s) in a releasable manner. For example, in some preferred embodiments, the volatile flavor-generating component comprises a matrix structure that defines multiple domains, and the flavoring agent is within the domain until it is released, eg, when the aerosol-forming substrate is exposed to external force. Has been captured in. Alternatively, the volatile flavor-generating component may include capsules. The capsule preferably comprises an outer shell and an inner core containing a flavoring agent. The outer shell is sealed prior to the application of external force, but is preferably fragile or fragile to allow the flavoring agent to be released when external force is applied. Capsules may be formed in a variety of physical configurations, including single-part capsules, multi-part capsules, single-walled capsules, multi-walled capsules, large capsules, and small capsules. Capsules and the like are included, but not limited to these.

If the volatile flavoring component comprises a matrix structure defining multiple domains that enclose the flavoring agent, the flavoring agent delivery member may gradually release the flavoring agent when the aerosol-forming substrate is exposed to an external force. Alternatively, if the flavor-generating component is a capsule that is either destroyed or ruptured to release the flavoring agent when the article for forming the aerosol is exposed to external force (eg,). , But not limited to, if the capsule comprises an outer shell and an inner core), the capsule may have any desired burst strength. Bursting strength is the force with which the capsule bursts (applied to the capsule from the outside of the aerosol-forming substrate). The burst strength may be the peak of the force vs. compression curve of the capsule.

The volatile flavor-generating component may be configured to release the flavoring agent in response to the activation mechanism. Such an activation mechanism may include applying a force to the volatile flavor-generating component, changing the temperature of the volatile flavor-generating component, a chemical reaction, or any combination thereof.

The method may include the step of adding a volatile flavor-generating component to a substance containing an aerosol-forming substrate and / or to a foam (reticulated or other foam) thereof. Additional or otherwise, the method may include the step of adding a volatile flavor-generating component to the cover layer (if provided) and / or its mold surface.

The aerosol-forming substrate preferably contains an aerosol-forming body.

As used herein, the term "aerosol-forming body" is any suitable that promotes aerosol formation during use and is substantially resistant to thermal decomposition at the operating temperature of the aerosol-forming substrate. Used to describe well-known compounds or mixtures of compounds. Suitable aerosol-forming bodies are well known in the art and include, for example, polyhydric alcohols (propylene glycol, triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (glycerol monoacetate, etc.). Diacetate or triacetate), and aliphatic esters of monocarboxylic acids, dicarboxylic acids or polycarboxylic acids (dimethyl dodecanenate, dimethyl tetradecanoate, etc.), but are not limited thereto.

Preferred aerosol-forming bodies are polyhydric alcohols such as propylene glycol, triethylene glycol, 1,3-butanediol and most preferably glycerin or mixtures thereof.

The aerosol-forming substrate may contain a single aerosol-forming body. Alternatively, the aerosol-forming substrate may include a combination of two or more aerosol-forming bodies.

The aerosol-forming substrate preferably has an aerosol-forming body content of more than 5% on a dry weight basis.

The aerosol-forming substrate may have an aerosol-forming body content of approximately 5% to approximately 30% on a dry weight basis.

In a preferred embodiment, the aerosol-forming substrate has an aerosol-forming body content of approximately 20% on a dry weight basis.

According to one aspect of the invention, an article for forming an aerosol is provided, the article comprising a peripheral surface surrounding an aerosol forming substrate, the article being in a heating chamber of an apparatus for generating an aerosol during use. The aerosol-forming substrate and / or its peripheral surface comprises first and second portions that are at least partially defined by fragile portions of the surface.

In some embodiments, the fragile moiety may include a separator and / or a frail line between the first and second moieties on the aerosol-forming substrate and / or the peripheral surface.

Advantageously, providing a fragile portion (eg, a separator and / or a frail line) allows the aerosol-forming substrate to be separated by the user into a first portion and a second portion, and thus each. Allows separate use in devices for generating aerosols. In this way, the article can provide multiple aerosol forming cycles in the apparatus for generating aerosols. Advantageously, the number of articles that need to be carried by the user of such a device is relatively small compared to conventional articles for forming aerosols. Furthermore, carrying an article for forming an aerosol according to the present invention is relatively easier and less annoying than the conventional article for forming an aerosol. In particular, the articles for forming aerosols according to the present invention occupy a relatively smaller volume than the plurality of conventional articles required to provide the same number of aerosol forming cycles. Further, the article for forming an aerosol according to the present invention may generate less noise during its transport than a plurality of conventional articles held in a case or pack.

In some embodiments, the peripheral surface may include, for example, a peripheral mold surface surrounding a molded aerosol-forming substrate. The article may include a cover layer that may include, demarcate, or be a peripheral surface (eg, a peripheral mold surface). The cover layer may be as described elsewhere herein (or may include such attributes).

In some embodiments, the first and second portions may have substantially the same shape and / or volume.

In some embodiments, the article and / or the aerosol-forming substrate and / or the first portion may have a substantially cylindrical shape. The article and / or aerosol-forming substrate and / or first portion may have diameter and length (eg, longitudinal dimensions) (eg, in cross section).

Articles and / or aerosol-forming substrates and / or first portions for forming aerosols may have a diameter of at least 5 mm, eg, from about 5 mm to about 12 mm, such as from about 5 mm to about 10 mm, or from about 6 mm. It may have a diameter of approximately 8 mm. In one embodiment, the article and / or aerosol-forming substrate and / or first portion for forming an aerosol may have an outer diameter of 7.2 mm +/- 10%.

The article and / or the aerosol-forming substrate and / or the first portion for forming the aerosol may have a length of about 30 mm to about 100 mm, for example about 45 mm. In embodiments, the article and / or aerosol-forming substrate and / or first portion for forming an aerosol may have a length of approximately 70 mm to approximately 120 mm.

As used herein, the term "diameter" is used to describe the maximum transverse dimension of an article for forming an aerosol. As used herein, the term "length" is used to describe the long axis maximum dimension of an article for forming an aerosol. As used herein, the term "major axis direction" is used to describe the direction between the ends of an article for forming an aerosol (eg, upstream and downstream ends) and is used to describe the "transverse direction". The term "" is used to describe a direction that is perpendicular to the major axis direction. As used herein, the terms "upstream" and "downstream" are the relative positions of an element, or part of an element, of an article for forming an aerosol with respect to the direction in which the user draws fluid through the article during its use. Used to describe.

In some embodiments, the article and / or the aerosol-forming substrate and / or the first portion may have a substantially flat first main surface. The article and / or the aerosol-forming substrate and / or the first portion may have a substantially flat second main surface. The first and second main surfaces may be substantially parallel to each other. The article and / or the aerosol-forming substrate and / or the first portion may have a substantially parallelepiped shape. The article and / or the aerosol-forming substrate and / or the first portion may have a width, a length and a thickness, for example the width, the length and the thickness are measured in directions perpendicular to each other. The thickness, if provided, may include the distance between the first main surface and the second main surface. The article and / or the aerosol-forming substrate and / or the first portion are at least 2: 1, for example at least 3: 1, 4: 1, 5: 1, 6: 1, 7: 1, 8: 1, 9: 1. Alternatively, it may have a ratio to a thickness of 10: 1. The width and / or length of the article and / or the aerosol-forming substrate and / or the first portion is approximately 2 mm to 120 mm, eg, approximately 3, 4, 5, 6, 7, 8, 9, 10-11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, It can be 110, 115, 120 mm. Articles and / or aerosol-forming substrates and / or first portions have a thickness of about 0.5 mm to 15 mm, such as about 0.5 or 1.0 mm to 1.5, 2.0, 2.5, 3. It can be 0, 3.5, 4.0, 4.5, 5.0, 6.0, 7.0, 8.0, 9.0, 10.0, 11.0 or 12.0 mm.

When weak lines are mentioned in the description below, it will be understood that any or all of the features may apply equally to fragile parts. Frail lines (if provided) may include continuous lines or interrupted lines. The frail line may be substantially a straight line. Alternatively, the frail line may be at least partially curved. If the article and / or the first portion and / or the aerosol-forming substrate have a thickness or diameter, the frail line may extend only partially through the thickness or diameter. Alternatively, the frail line may extend through the thickness or diameter. If the article and / or the first portion and / or the aerosol-forming substrate have a width, the frail line may extend across only a portion of the width. Alternatively, the frail line may extend across the entire width.

In some embodiments, the frail lines may include a plurality of frail lines (eg, first and second frail lines). The first weak line may be separated from the second weak line. The first frail line may be substantially parallel to or at right angles to the second frail line. The first frail line is only a distance substantially equal to the first and / or second dimension (eg, its thickness, width or length) from the second frail line and / or from the edge of the article. It may be separated. When a frail line comprises a plurality of frail lines, one frail line may include continuous lines and another of the plurality of frail lines may include interrupted lines. Additional or otherwise, one or more of the frail lines may have different properties (eg, through the thickness or diameter of the article or width) than the other one or more of the frail lines. May have (with respect to extending across). Additional or otherwise, one or more of the frail lines may have a tear strength different from that of the other one or more of the frail lines.

The separator (if provided) may include a portion or portion of the peripheral surface, eg, may be integrally formed with it, or may be attached to it. Alternatively, the separator may include, for example, a separate element separate from the peripheral surface. The separator may be configured or arranged to completely separate the first part from the second part. Alternatively, the separator (eg, such that the first and second parts are at least partially attached or combined), partially attaches the first part from the second part. It may be configured or arranged so as to be separated only into. The separator may comprise one frail line, for example the frail line may be provided in at least a portion of the separator or through at least a portion of the separator.

Separators can be formed from one or more thermostable materials that can undergo chemical and / or phase changes, eg, at temperatures above the temperature at which the volatile compound is released from the aerosol-forming substrate. The separator may include polymers and / or wood materials and the like.

Alternatively, the separator may be formed from a material selected to undergo a chemical and / or phase change at a temperature below the temperature at which the volatile compound is released from the aerosol-forming substrate. In embodiments, the separator may contain a volatile flavor-generating component, such as an additive (eg, a flavoring agent).

According to one aspect of the invention, a method for producing or producing an article for forming an aerosol is provided, wherein the method is:
a) A step of providing a surface for defining the perimeter of an article for forming an aerosol, and
b) The process of providing the aerosol-forming substrate and
c) A step of forming a fragile portion on the aerosol-forming substrate and / or the surface thereby at least partially defining the first and second portions of the aerosol-forming substrate.
d) The step of arranging the surface and the aerosol-forming substrate so that the surface surrounds the periphery of the aerosol-forming substrate is included.

Step c) forms a frail line on the aerosol-forming substrate, thereby at least partially defining its first and second parts and / or the aerosol-forming substrate in the first and second parts (step c). For example, the first and second parts) may include at least a partial separation. In some embodiments, step c) can occur before step b), at the same time as step b), or after step b). Forming a frail line pushes the forming tool into an aerosol forming substrate to locally deform and / or make a cut in it, eg, press the forming tool against a surface to define the perimeter of the article. Thereby it may include locally deforming and / or making a notch in the aerosol-forming substrate. Step c) may include pressing the forming tool against both sides and / or the surface of the aerosol forming substrate, eg, at least partially simultaneously or continuously, to define the periphery of the article.

Aerosol-forming substrates can be formed by extrusion or molding. If the aerosol-forming substrate is formed by molding, this molding can occur at least partially on the surface to define the perimeter of the article (eg, if the surface can include a molded surface). If the aerosol-forming substrate is formed by molding, frail lines can be formed at least partially during the molding of the aerosol-forming substrate.

If the aerosol-forming substrate is at least partially separated into first and second parts by a separator, this may include providing a separator between the first and second parts. The separator may be pushed into the aerosol forming substrate. Alternatively, the aerosol-forming substrate may be formed at least partially around the separator, eg, may be molded around it.

In some embodiments, the step d) of arranging the surface and the aerosol-forming substrate such that the surface surrounds the aerosol-forming substrate may include wrapping the aerosol-forming substrate with the surface. Additional or otherwise, step d) is to form an aerosol-forming substrate on the surface, eg, at least partially deposit a fluid aerosol-forming substrate on the surface to at least partially deposit the aerosol-forming substrate on the surface. It may be possible to solidify or include solidification.

According to one aspect of the invention, a method of using an article for forming an aerosol is provided, wherein the method is a step of providing an apparatus for generating an aerosol, wherein the apparatus comprises a heating chamber. The steps provided, the steps of providing an article for forming an aerosol containing an aerosol-forming substrate surrounded by a peripheral surface or a mold surface, and the formation of an aerosol in the heating chamber of the apparatus for generating the aerosol. It includes a step of inserting an article for forming an aerosol and a step of generating an aerosol from an aerosol-forming substrate of the article for forming an aerosol.

Articles for forming aerosols may include a cover layer that may include or demarcate peripheral surfaces or mold surfaces. The method of use may include removing the cover layer before inserting the article for forming the aerosol into the heating chamber of the device for generating the aerosol. Alternatively, the article for forming the aerosol is placed in the heating chamber of the device for generating the aerosol, with the cover layer still providing a surface or mold surface that surrounds the periphery of the aerosol forming substrate. It may be inserted.

All scientific and industrial technical terms used herein have meanings commonly used in the art, unless otherwise specified. The definitions provided herein are intended to facilitate the understanding of certain terms frequently used herein.

Throughout the description and claims herein, the terms "comprising" and "including", as well as variations thereof, mean "including, but not limited to," other parts, additives, configurations. It means that you do not intend (and do not exclude) to exclude elements, integers, or steps. Throughout the description and claims herein, the singular includes the plural and vice versa, except where the context requires otherwise. In particular, where indefinite articles are used, the specification should be understood as contingent not only in the singular but also in the plural, unless the context requires that it be not.

For the avoidance of doubt, any feature of the features described herein applies equally to any aspect of the invention. Within the scope of this application, the various embodiments, embodiments, examples and alternatives presented in the paragraphs, claims and / or description and drawings described above, and in particular in their particular individual features, are individual. It is explicitly assumed that it can be used in or in any combination. The features described in connection with one aspect or embodiment of the invention are applicable to all aspects or embodiments as long as these features are not incompatible.

Here, the present invention will be further described with reference to the following accompanying drawings, but only as an example.

FIG. 1 is a schematic cross-sectional view of an article for forming an aerosol according to an embodiment of the present invention. FIG. 2 is a flow chart illustrating a method of manufacturing an article for forming an aerosol, which is shown in FIG. FIG. 3 is a schematic perspective view of an article for forming an aerosol according to a further embodiment of the present invention. FIG. 4 is a schematic cross-sectional view cut along the lines A to A of FIG. FIG. 5 is a flow chart illustrating a method of manufacturing an article for forming an aerosol, which is shown in FIG.

Here, with reference to FIG. 1, an article 1 for forming an aerosol according to an embodiment of the present invention is shown. Article 1 includes a peripheral cover layer 2 comprising or defining a mold surface 20 surrounding a molded aerosol-forming substrate 3.

The cover layer 2 is made of paper and in this embodiment has the form of a net or woven fabric having a plurality of openings throughout its thickness. However, in embodiments, the cover layer 2 may have a solid surface without or with openings and / or is formed from any suitable material, such as a polymeric material and / or paper. You may.

The aerosol-forming substrate 3 comprises, in this embodiment, a reticulated open-cell foam of reconstituted tobacco (eg, stem, etc.). However, in embodiments, the aerosol-forming substrate 3 may be supported or supported by a carrier material, which itself is in the form of a foam (eg, open cell or reticulated open cell foam). When the carrier material is provided, the aerosol-forming substrate 3 can be in any suitable form for being retained by the carrier material. For example, the aerosol-forming substrate 3 may be in the form of a solid (eg, powder) or fluid.

The aerosol-forming substrate 3 is impregnated with nicotine and glycerin in this embodiment. However, in embodiments where the aerosol-forming substrate 3 is carried in the carrier material, the carrier material can be impregnated with nicotine and / or glycerin. In addition, or otherwise, in addition to or instead of nicotine and glycerin, any suitable additive may be impregnated into the aerosol-forming substrate 3 (or carrier material, if provided). .. Suitable additives include tobacco and non-tobacco fibers, aerosol-forming bodies, wetting agents, plasticizers, volatile flavor-generating ingredients, flavoring agents, fillers, aqueous and non-aqueous solvents, and combinations thereof. Not limited to these. In embodiments, the cover layer 2 may be additionally or otherwise impregnated with nicotine, glycerin and / or any other suitable additive. In embodiments, nicotine, glycerin and / or any other suitable additive may be provided additionally or otherwise on the mold surface 20 of the cover layer 2.

Here, with reference to FIG. 2, a flow diagram illustrating a method of manufacturing an article for forming an aerosol, which is shown in FIG. 1, is shown.

The method comprises a first step S1 comprising providing a cover layer 2 comprising or defining a mold surface 20 shaped to demarcate the periphery of an article 1 for forming an aerosol.

In the second step S2, a substance containing an aerosol-forming substrate (for example, at least a partially liquid substance) is introduced onto the mold surface 20 of the cover layer 2. In embodiments, aerosol-forming substrates include tobacco, such as reconstituted tobacco or waste tobacco products (such as stems). The substance may be a slurry formed by a conventional method, as is well known to those skilled in the art.

In this embodiment, the substance (eg, slurry) is formed into a foam in the third step S3 by foaming with a gas (eg, a gas blown into the substance and / or a gas generated within the substance). On the other hand, the substance (eg, slurry) is located on the mold surface 20. However, in the embodiment, the substance (eg, slurry) may be foamed before being introduced onto the mold surface 20 in the second step S2.

The foam material is reticulated in step S4, which also occurs in this embodiment after the material (eg, slurry) is introduced onto the mold surface 20. However, in the embodiment, the fourth step S3 of reticulation may occur before contacting the mold surface 20.

Nicotine and glycerin are provided on the mold surface 20 before introducing the substance (eg, slurry) onto the mold surface 20 in step S2. Nicotine and glycerin may be sprayed, rolled, dip-coated or otherwise deposited on the mold surface 20. Nicotine and glycerin can be provided simultaneously or continuously on the mold surface 20. In this embodiment, nicotine and glycerin are impregnated into the material (eg, slurry) when the material is introduced onto the mold surface 20, and as a result, are impregnated into the foamed aerosol-forming substrate 3. However, in embodiments, such impregnation may include providing nicotine and / or glycerin directly into the substance (eg, slurry) or foam material (eg, by spraying). In embodiments, the cover layer 2 may be formed from a material that is at least partially absorbent and retains at least partially nicotine and / or glycerin (and / or any other suitable additive). Can be configured as

The reticulated foam aerosol-forming substrate can then be cured, or otherwise dried, or dried. In this way, the article 1 for forming the aerosol is formed.

Referring now to FIGS. 3 and 4, an article 11 for forming an aerosol is shown according to a further embodiment of the invention, where similar reference numbers starting with "1" refer to similar features thereof. Similar features are not further described herein. The article 11 shown in FIGS. 3 and 4 has a different cross-sectional shape (the article 11 has a rectangular cross-sectional shape rather than a circular cross-sectional shape of the article 1), and a weak line W (thus, thereby). It differs from Article 1 shown in FIG. 1 in that it provides a fragile portion) to the aerosol forming substrate 13.

The frail line W defines the first and second portions 13a, 13b of the aerosol forming substrate 13, as is particularly apparent in FIG. The first and second portions 13a, 13b have generally similar shapes and volumes in this embodiment. However, in embodiments, the first and second portions 13a, 13b may have different shapes and / or volumes.

The frail line W includes, in this embodiment, a continuous and uninterrupted line extending across the width w of the article 11. The frail line W does not extend through the thickness t of the aerosol-forming substrate 13 in this embodiment so that the first and second portions 13a, 13b remain partially bonded to each other. At the time of use, the user can selectively separate the first and second portions 13a, 13b from each other by the weak line W. The first portion 13a of the aerosol forming substrate 13 can then be used in an apparatus for generating aerosols (not shown), while the second portion 13b is there for future use. Is held in. A portion of the cover layer 12 extends into the weak line W, thereby forming the separator S.

The article 11 for forming an aerosol is formed by the method shown in FIG. In the first step S5, the cover layer 12 is provided. In the second step S6, the aerosol forming substrate 13 is provided. The cover layer 12 is wrapped around the aerosol-forming substrate 13 (or otherwise placed around the aerosol-forming substrate) in step S7. A portion of the cover layer 12 is then in the fourth step S8, using a shaped and sized press tool (not shown) to form the frail line W, at the desired frail line W shape and position. It is pushed into the aerosol forming substrate 13. The pressure acting on the aerosol-forming substrate 13 deforms it, forming a weak line W. The portion of the cover layer 12 pushed into the aerosol-forming substrate remains in the weak line W in this embodiment, thereby at least portion of the second portion 13b to the first portion 13a of the aerosol-forming substrate 13. A separator S is formed so as to be separated. However, in embodiments, the cover layer 12 can at least partially recede from the weak line W after the formation of the weak line W (and thereby revert to or shape the material prior to the application of pressure to the material). It may be formed at least partially from the material.

In embodiments, the aerosol-forming substrate 13 may include a plurality of frail lines W (eg, two, three, four, or more frail lines). In embodiments, one or more of the additional weak lines may be substantially parallel to or perpendicular to the first weak line W.

As is understood, in embodiments the frail line W can extend over only a portion of the width w of the article 11. Additional or otherwise, the frail line W may not have a continuous line and may instead include one or more interruptions along its length. If the frail line W extends only partially across the width w of the article 11 and / or includes a discontinuous line across it, the frail line W may extend through the thickness t of the aerosol forming substrate 13. .. When the frail line W extends through the thickness t of the aerosol-forming substrate 13, the portion of the cover layer 12 extending into the frail line W contacts the cover layer 12 on the front surface of the aerosol-forming substrate 13 and / Or they can be combined. Such a bond, with an adhesive and / or by one or more fixtures and / or thermally, brings a portion of the cover layer 12 within the weak line W to the cover layer 12 on the front side surface of the aerosol forming substrate 13. It can be achieved by joining.

In embodiments, the frail line W can be formed by pushing the cover layer 12 into the aerosol-forming substrate 13 simultaneously or continuously on both sides thereof.

While it has been described that the frail lines W are formed only by pushing the cover layer into the aerosol-forming substrate, this does not have to be the case, instead the frail lines cover the aerosol-forming substrate 13. It may be formed at least partially before being covered with twelve. In embodiments, the aerosol-forming substrate 13 may be directly pressed to form a weak line W. In embodiments, the aerosol-forming substrate may be molded in a mold with protrusions arranged to at least partially demarcate the weak line W. In some embodiments, the frail line W may be formed by penetrating the cover layer 12 with one or more through edges.

In an alternative embodiment, the frail line W may extend across the width w of the aerosol forming substrate 13 and through the thickness t thereby separating the first and second portions 13a, 13b from each other. good. The portion of the cover layer 12 of the frail line W may be at least partially bonded or affixed to the cover layer 12 on the front surface of the aerosol forming substrate 13, with the first and second portions 13a, 13b. Separated from each other. If the cover layer 12 comprises such a coupling portion between the first portion and the second portion, a weak line may be provided at the coupling portion of the cover layer 12 (which comprises the separator). For example, one or more openings may be provided through the joint portion of the cover layer. These openings can be formed by blades or other sharp instruments.

The schematic diagram is not necessarily proportional to the actual size, is presented for the purpose of illustration, and is not limited. The drawings describe one or more aspects described in the present disclosure. However, of course, other aspects not depicted in the drawings fall within the scope of the present disclosure.

Claims (16)

A method of manufacturing articles for forming aerosols,
a) A step of providing a cover layer comprising, defining, or providing a mold surface to demarcate the perimeter of an article for forming an aerosol.
b) A step of depositing a substance that is at least partially fluid and contains an aerosol-forming substrate on the mold surface.
c) A method comprising the step of providing an article for forming an aerosol, which at least partially solidifies or enables it, thereby having a periphery formed from the cover layer. The method according to claim 1, comprising the step d) of foaming the substance. The method of claim 2, wherein step d) occurs after step b). The method according to claim 2 or 3, comprising the step e) of forming the foam into a net. The method of claim 4, wherein step e) occurs after step b). The item according to any one of claims 1 to 5, which comprises a step f) of adding one or more of a volatile flavor-generating component, an aerosol-forming body, and nicotine to the mold surface and / or the substance. Method. 6. The step 6 includes adding the one or more of the volatile flavor generating component, the aerosol-forming body, and nicotine to the mold surface before the step b). The method described in. Any one of claims 1-7, comprising the step g) of forming a frail line on the surface of the substance and / or the mold thereby at least partially defining the first and second parts of the substance. The method described in. 13. Method. An article for forming an aerosol, wherein the article comprises a cover layer comprising, providing, or defining a peripheral mold surface surrounding a molded aerosol forming substrate, the article generating an aerosol during use. An article that can be inserted into the heating chamber of the device for. 10. The article of claim 10, wherein the aerosol-forming substrate comprises first and second portions of the aerosol-forming substrate and / or at least partially defined by fragile portions of the peripheral surface. An article for forming an aerosol, wherein the article comprises a peripheral surface surrounding an aerosol forming substrate, and the article can be inserted into a heating chamber of an apparatus for generating an aerosol during use, said the aerosol. Articles in which the forming substrate comprises first and second portions of the aerosol forming substrate and / or at least partially defined by fragile portions of the peripheral surface. 12. The article of claim 11 or 12, wherein the fragile portion comprises a separator and / or a frail line on the aerosol-forming substrate between the first and second portions. The article according to claim 11, claim 12 or claim 13, wherein the article comprises a separator that at least partially defines the first and second portions, and the peripheral surface comprises the separator. The article according to any one of claims 11 to 14, wherein the first portion and the second portion have substantially similar shapes and / or volumes. The article according to any one of claims 10 to 15, wherein the aerosol-forming substrate contains, for example, a foam formed from reconstituted tobacco, for example, a reticular foam.

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