TWI832918B - Smoking substitute consumable, method for manufacturing heat-not-burn (hnb) consumable, hnb consumable, system comprising hnb consumable, and method of using the system - Google Patents

Abstract

The present disclosure relates to a method of forming an HNB consumable comprising a slurry-type aerosol-forming substrate (e.g. tobacco) dosed with a flavourant, and HNB consumables formed by that method.

Description

Smoking substitute consumables, methods for manufacturing heat-not-burn (HNB) consumables, HNB consumables, systems including HNB consumables, and methods of using the systems

The present disclosure relates to a method of forming HNB consumables for use in a smoking alternative system and HNB consumables formed by such methods.

During the manufacturing process of tobacco products, such as cigarettes, tobacco waste is generated. Tobacco waste generally takes the form of tobacco ash, leaves, or stems. Tobacco waste can be collected and processed to provide so-called reconstituted tobacco or "recon".

Two distinct methods are most commonly used to manufacture reconstituted tobacco. These methods are: 1) the papermaking process (which is used to provide a "paper reconstitute"), and ii) slurry casting (which is used to provide a "slurry type reconstituted product"). "thing"). The products resulting from these different processes have significantly different properties and characteristics. For example, pulp-type reconstituted products generally have improved aroma/flavor and nicotine content compared to paper reconstituted products, but pulp-type reconstituted products generally break more easily and often have poorer quality uniformity.

During slurry casting, tobacco waste is ground into a fine powder, mixed with an aqueous solvent (usually water) and combined with a binder. The resulting slurry may be subjected to further grinding to further reduce the particle size of the tobacco material. The slurry is then cast onto a surface and dried to form sheets. The dried sheets can be shredded for use in a variety of tobacco products, such as cigarette filler.

In the papermaking process, tobacco waste is pounded in the presence of an aqueous solvent to digest and process the tobacco into processable fibers. Subsequently, water-soluble compounds present in tobacco are extracted into an aqueous solvent. Separate the aqueous extract and the insoluble fibrous fraction. The separated fibrous portion (which may also be described as "pulp") undergoes further processing via typical papermaking procedures to form a base sheet. The aqueous extract is concentrated and then re-applied to the base sheet. The base sheet is then dried to form paper.

It is generally believed that smoking tobacco exposes smokers to potentially harmful substances. It is generally believed that a large number of potentially harmful substances are produced by the heat caused by the combustion and/or ignition of burning tobacco components in tobacco and the tobacco smoke itself.

Conventional combustible smoking articles (such as cigarettes) generally include a cylindrical tobacco rod and usually also include a cylindrical filter. The cylindrical tobacco rod includes shredded tobacco surrounded by a wrapper, and the filter is formed with the wrapped tobacco rod. axially aligned in adjacent relationship. Filters generally include filter material enclosed by a plug. The wrapped tobacco rod and filter are joined together by a wrapped tipping tape that encompasses the entire length of the filter and adjacent portions of the wrapped tobacco rod. Such conventional cigarettes are used by lighting the end opposite the filter and burning the tobacco rod. Smokers receive mainstream smoke into their mouths by puffing on the mouth end or filter end of a cigarette. The ignition of organic materials, such as tobacco, is known to produce tar and other potentially harmful by-products. Various smoking alternative systems (or "alternative smoking systems") have been proposed to avoid smoking tobacco.

Such smoking replacement systems could form part of nicotine replacement therapy for people who wish to stop smoking and overcome their dependence on nicotine.

Smoking alternative systems include electronic systems that allow users to simulate the action of smoking by generating smoke (also called "vapor") that is drawn into the lungs through the mouth (inhalation) and then exhaled. Inhaled smoke typically contains nicotine and/or flavoring, which has none or fewer of the odors and health risks associated with traditional smoking.

Generally speaking, smoking alternative systems aim to provide an alternative to the smoking ritual while providing a similar experience to users and providing satisfaction to those who have experience with traditional smoking and combustible tobacco products. Some smoking alternative systems use a smoking alternative article that is designed to resemble a traditional cigarette and is cylindrical in form with a mouthpiece at one end.

Over the past few years, the popularity and use of smoking replacement systems has grown rapidly. Although originally marketed as an aid to assist habitual smokers who wish to quit smoking tobacco, consumers are increasingly viewing smoking replacement systems as desirable lifestyle accessories.

There are many different categories of smoking replacement systems, each utilizing different smoking replacement methods.

One method used for smoking alternative systems is the so-called "heat not burn" ("HNB") method, in which tobacco (rather than "e-liquid") is heated or warmed to release vapor. The tobacco may be tobacco leaves or reconstituted tobacco. The vapor may contain nicotine and/or flavorings. In the HNB method, the intention is that the tobacco is heated but not burned, ie the tobacco does not undergo ignition.

A typical HNB smoking replacement system may include equipment and consumables. Consumables may include tobacco materials. Equipment and consumables can be configured to be physically coupled together. In use, heat may be imparted to the tobacco material by heating means of the device, wherein the flow of air through the tobacco material causes moisture in the tobacco material to be released as vapor. The vapor may also be formed from a carrier in the tobacco material and additional volatile compounds released from the tobacco (the carrier may include, for example, propylene glycol and/or vegetable glycerin). The released vapor can become entrained in the air flow drawn through the tobacco.

As the vapor passes through the filament (entrained in the air flow) from the inlet to the mouthpiece (outlet), the vapor cools and condenses to form aerosol for inhalation by the user. Smoke will typically contain volatile compounds.

In the HNB smoking alternative system, it is believed that heating rather than burning the tobacco material results in fewer or smaller amounts of the more harmful compounds typically produced during smoking. Thus, the HNB approach can reduce odor and/or health risks that may be caused by combustion, ignition, and pyrolytic degradation of tobacco.

Improvements in the design of HNB consumables are needed to enhance the user experience and improve the functionality of HNB smoking replacement systems.

This disclosure has been designed with the above considerations in mind.

In the broadest sense, the present disclosure relates to methods of forming HNB consumables that include an aerosol-forming substrate having an increased concentration of volatile compounds.

According to a first aspect, the present invention provides a method of forming an HNB consumable comprising an aerosol-forming substrate, the method comprising a slurry type process for forming recombinant plant material, wherein flavoring is provided in the slurry prior to casting into a sheet. in the body.

In contrast to the papermaking process, the reference to "slurry type" corresponds to the reconstituted plant material produced by slurry casting.

By using a flavored aerosol-forming substrate that itself includes volatile compounds, the amount/concentration of volatile compounds can be increased to provide a vapor/aerosol containing a higher concentration of volatile compounds to the user. This may provide enhanced recreational and/or medical benefits to the user upon inhalation. Also, current flavoring options for HNB consumables are limited. Therefore, by adding flavoring to the aerosol-forming substrate, the user will experience enhanced and varied flavors from the resulting HNB consumable.

The optional features are now listed. These features are applicable individually or in any combination with any aspect.

A method for manufacturing a first aspect of a heat-not-burn (HNB) consumable comprising an aerosol-forming substrate (wherein the aerosol-forming substrate is a slurry type of recombinant plant material) includes the following steps: combining ground plant material with an aqueous medium to form a slurry; providing flavorings in the slurry; casting the slurry to form a sheet; drying the sheet to form an aerosol-forming substrate; and converting the aerosol-forming substrate Part of the material is merged into HNB consumables.

The aerosol-forming substrate formed by the present method can be heated to release at least one volatile compound that can form aerosol. The aerosol-forming substrate may be located at the upstream end of the consumable.

As used herein, the terms "upstream" and "downstream" are intended to refer to the direction of flow of vapor/smoke, i.e. where the downstream end of the consumable is the mouth end or outlet where the smoke leaves the consumable for inhalation by the user flow direction. The upstream end of the consumable is the opposite end of the downstream end.

To generate aerosol, the aerosol-forming substrate includes at least one volatile compound that is intended to be vaporized/aerosolized and that can provide recreational and/or medical benefits to the user when inhaled. Suitable chemically and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opium and opiates, norpseudoephedrine and cathinones, kava lactones , myristyl ether, beta-carboline alkaloids, salvinorin A, and any combination, functional equivalent, and/or synthetic substitute of the foregoing items.

Binders can also be included in the slurry. Accordingly, the method may further include the step of incorporating the binder into the slurry. The ground tobacco can be combined with a binder before being combined with the aqueous medium. Alternatively, the binder can be combined with the aqueous medium prior to combining the aqueous medium with the ground tobacco.

Suitable adhesives are known in the art and can be used to bind together the components of the aerosol-forming substrate. Binders may include starch and/or cellulose binders (such as methylcellulose, ethylcellulose, hydroxypropylcellulose, hydroxyethylcellulose, and carboxymethylcellulose), tree Gums (such as xanthan gum, guar gum, acacia gum, and/or carob gum), organic acids, and their salts (such as alginic acid/sodium alginate, agar, and pectin).

Preferably, the binder is included at a level that results in a binder content of 5 to 20 weight percent (eg, about 6 to 8 weight percent) of the aerosol-forming substrate. The upper limit of binder is preferably up to 15 weight percent, for example up to 10 weight percent. Preferably, the binder content is greater than 5 weight percent.

The slurry may also contain fillers, humectants, and/or preservatives. These can be combined with the ground plant material before being combined with the aqueous medium, or can be added separately to the slurry.

Preferably, the total solids content of the slurry is between 15% and 30% by weight of the total slurry. Within this preferred range, about 50 to 90% of the total solids content of the slurry should be plant material. The plant material content of the slurry is not critical, but preferably a minimum amount of aqueous medium is used to avoid leaching of plant material solubles into the aqueous medium.

The slurry is formed by mixing the various components of the slurry. This can be accomplished using high energy mixers or high shear mixers to homogenize the slurry. During mixing, the slurry can optionally be heated.

Additionally, the slurry can be vibrated to assist in homogenizing the slurry. This can be accomplished by vibrating a tank or silo containing the slurry.

After mixing, the slurry is cast onto a moving support surface (such as a dryer belt) to form a sheet. Casting of the sheet may be accomplished by a roller coater system or laminator, or any other method suitable in the art. Preferably, the moisture of the sheet when cast is between 60 and 80 percent of the total weight of the cast slurry. The cast sheet is then dried, such as by exposure to elevated temperatures and/or reduced pressure, to remove excess moisture content from the sheet. Suitable drying methods include steam dryers and/or heated air dryers. Alternatively, the sheet can be dried under ambient conditions.

Seasonings can be provided in solid or liquid form. These may include menthol, peppermint, spearmint, licorice, chocolate, fruit flavors (including, for example, citrus, cherry, etc.), vanilla, spices (for example, ginger, cinnamon), coffee, eucalyptus, and tobacco flavors. The flavorings may be uniformly dispersed throughout the aerosol-forming substrate, or may be provided in isolated locations and/or in varying concentrations throughout the aerosol-forming substrate. Preferably, the flavoring is uniformly dispersed in the slurry, resulting in uniform dispersion throughout the aerosol-forming substrate. The ability to disperse flavorings evenly throughout the aerosol-forming substrate is a benefit of this method. The result is an improved user experience and uniformity of flavor distribution.

Advantageously, these flavorings have been found to be desirable by the user and also provide the user with a satisfying flavored "hit". Additionally, a varied and enhanced flavor experience is achieved.

The added flavoring content of the aerosol-forming substrate may be at least 0.1 weight percent (eg at least 0.5 weight percent, such as at least 1 weight percent, such as at least 2 weight percent, such as at least 5 weight percent, such as at least 10% by weight, for example at least 15% by weight).

The added flavoring content of the aerosol-forming substrate may have an upper limit of up to 20 weight percent (eg up to 15 weight percent, eg up to 10 weight percent) of the aerosol-forming substrate.

Preferably, the seasoning concentration is 0.1 to 15 weight percent. Still more preferred is a flavoring concentration of 0.1 to 5 weight percent of the aerosol forming substrate.

Preferably, the flavoring is menthol.

It is further preferred that the flavoring is synthetically derived menthol. Advantageously, this source of menthol is not naturally derived. Generally, naturally derived menthol is provided in the form of peppermint or peppermint extract. Thus, the use of synthetic menthol eliminates the presence of undesirable ingredients present in peppermint or peppermint extract.

Advantageously, because the present invention is primarily intended to provide methods for forming alternative smoking consumables, non-tobacco flavorings are used to provide users with unconventional flavors that are not normally experienced. Therefore, a changed and enhanced user experience is provided.

Preferably, the flavoring is provided in the base liquid. Advantageously, by "pre-mixing" the flavoring with the base liquid before combining the "premix" with the slurry, the flavoring can be delivered to the slurry more safely, efficiently, and reproducibly. Specifically, premixing the seasoning with the base liquid reduces the volatility of the seasoning, making it easier to handle and handle. Additionally, the benefit of the resulting HNB consumable is that it avoids exposing the user to harmful pyrophoric products when using the consumable, but without loss of flavor.

Preferred base liquids are polyols. Suitable polyols include propylene glycol (PG), triethylene glycol, 1,2-butanediol, and vegetable glycerin (VG), and their esters (such as glyceryl monoacetate, glyceryl diacetate, or glyceryl triacetate). ). Specifically, propylene glycol and vegetable glycerin are preferred.

Preferably, the content of the added seasoning contained in the base liquid is in the range of 1 to 95 weight percent based on the total weight of the seasoning and the base liquid.

Particularly preferred seasoning content is 1 to 50 weight percent, such as 1 to 25 weight percent, such as 1 to 15 weight percent, based on the total weight of seasoning and base liquid. Advantageously, this provides sufficient dilution of the seasoning with the base liquid to provide safer handling of the seasoning during processing. Also, such combinations allow for good dispersion of the flavorings within the base liquid.

The aerosol-forming substrate may comprise at least 50 weight percent plant material, such as at least 60 weight percent plant material, such as about 65 weight percent plant material. The aerosol-forming substrate may include 80 weight percent or less plant material, such as 75 or 70 weight percent or less plant material.

The plant material may include at least one plant material selected from the list including: Amaranthus dubius, Arctostaphylos uva-ursi (bearberry), Argemone mexicana , Amica , Artemisia vulgaris , Yellow Tees, Galea zacatechichi , Canavalia maritima (convalylola) , Cecropia mexicana (Guamura), Cestrum noctumum , Cynoglossum virginianum (Cynoglossum virginianum), Cytisus scoparius , Damiana , Entada rheedii, Eschscholzia califomica (flower root), Fittonia albivenis , Hippobroma longiflora, Humulus japonica (Japanese hop), Humulus lupulus , Lactuca virosa , Laggera alata , Leonotis leonurus , Leonurus cardiaca , Leonurus sibiricus (Honeyweed), Lobelia cardinalis , Lobelia inflata , Lobelia siphilitica , Nepeta cataria (False Nepeta), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Poppy, Passiflora incamata (Passion Flower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant Head), Salvia divinorum , Salvia dorrii (tobacco sage), Salvia species (sage), Scutellaria galericulata , Scutellaria lateriflora , Scutellaria nana , Scutellaria species (head grass), Sida acuta (wire grass), Sida rhombifolia , Silene capensis, Syzygium aromaticum (clove ), Tagetes lucida (Mexican tarragon), Tarchonanthus camphoratus, Tumera diffusa (Mexican beet), Verbascum (mullein), Zamia latifolia (Zinnia (Maconha Brava)), and any combinations, functional equivalents, and /or synthetic alternatives.

Preferably, the plant material is tobacco. Any type of tobacco can be used. This includes, but is not limited to, flue-cured, burley, Maryland, dark-cured, oriental, dark-cured, perique, and goldenrod. This also includes mixtures of the tobaccos mentioned above.

Any suitable part of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

Tobacco may include one or more of the following: leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenized tobacco, chopped tobacco, extruded tobacco, cut tobacco, and/or reconstituted tobacco Tobacco (e.g. pulp reconstitution or paper reconstitution).

Preferably, the plant material is tobacco.

Since the present invention is primarily intended to provide smoking consumables, the use of tobacco provides a slurry type of recombinant plant material having the inherent properties of tobacco, such as texture, aroma, and nicotine content.

Preferably, the plant material is ground to a particle size of less than 120 microns. Particle sizes greater than 150 microns are undesirable as they are associated with the formation of defects and non-homogeneous areas in the sheet formed by the casting slurry. In detail, a particle size of 30 to 120 microns is preferred.

The method may include the step of winding the formed sheet onto a tube.

The method may further comprise the step of aggregating the homogenized slurry to reconstitute the tobacco sheets or aggregating the chips/rods formed from such sheets.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage per square meter greater than or equal to 100 g/m ² , such as greater than or equal to 110 g/m ² , such as greater than or equal to 120 g/m ² .

The sheet may have a grammage per square meter of less than or equal to 300 g/m ² , such as less than or equal to 250 g/m ² or less than or equal to 200 g/m ² .

The sheet may have a grammage per square meter between 120 and 190 g/ ^m2 .

In some embodiments, the sheet used to form the aerosol-forming substrate has a density of less than 1100 mg/cm ³ , preferably less than 1000 mg/cm ³ , and more preferably less than 900 mg/cm ³ .

In some embodiments, the sheet used to form the aerosol-forming substrate has less than 0.09 mg/mm ² , preferably less than 0.085 mg/mm ² , preferably less than 0.08 mg/mm ² , and more preferably less than 0.075 mg/mm 2 mm ² mass/surface area.

In some embodiments, the aerosol-forming substrate may have a thickness of less than about 1 mm, preferably less than about 0.5 mm, preferably between about 0.1 and 0.3 mm (eg, about 0.2 mm).

The step of casting the slurry to form a sheet may thus include the step of extending the slurry to form a sheet that, when dried, has a thickness and/or density as set forth herein.

The aerosol-forming substrate may additionally include one or more additives selected from humectants, fillers, aqueous/non-aqueous solvents, and binders and provided during the formation method (eg, provided in a slurry).

Moisturizers are provided as vapor generators - the vapor generated helps carry volatile active compounds and increases visible vapor. Suitable humectants include polyols (such as propylene glycol (PG), triethylene glycol, 1,2-butanediol, and vegetable glycerin (VG)) and their esters (such as glyceryl monoacetate, glyceryl diacetate, or glyceryl diacetate). triacetin). They may be present in the aerosol-forming substrate in an amount between 1 and 50 weight percent.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1 weight percent, such as at least 2 weight percent, such as at least 5 weight percent, such as at least 10 weight percent, such as at least 20 weight percent, such as at least 30 weight percent, of the plant material. Or for example at least 40 weight percent.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40% by weight, such as at most 30% by weight, or for example at most 20% by weight.

Preferably, the humectant content is from 1 to 40 weight percent of the aerosol-forming substrate, for example from 1 to 20 weight percent.

Suitable fillers are known in the art and can be used to strengthen the aerosol-forming substrate. Fillers may include fibrous (non-tobacco) fillers such as cellulosic fibers, lignocellulosic fibers (eg, wood fibers), jute fibers, and combinations of the foregoing.

Preferably, the filler content is 5 to 10 weight percent of the aerosol-forming substrate, for example about 6 to 9 weight percent.

The aerosol-forming substrate may include aqueous and/or non-aqueous solvents. In some embodiments, the aerosol-forming substrate has a water content of between 5 and 10 weight percent (eg, between 6-9 weight percent, such as between 7-9 weight percent).

The aerosol-forming substrate can be formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm (for example between 6 and 9 mm or between 6 and 8 mm, for example about 7 mm). It may have an axial length of between 10 and 15 mm, such as between 11 and 14 mm, such as about 12 or 13 mm.

The aerosol-forming substrate may be surrounded by a wrapper, such as a paper wrapper. The wrapping layer may cover the inner foil layer, or may include a paper/foil laminate structure (with the foil being innermost).

The consumable may include at least one filter member. There may be a terminal filter member at the downstream/oral end of the consumable. There may be an upstream filter member, which may be axially adjacent or axially spaced from the terminal filter member. The upstream filter member may be at least partially (eg completely) surrounded by a (paper) wrapping layer.

The filtration member or at least one of the filtration members (eg, terminal filtration member and/or upstream filtration member) may comprise cellulose acetate fiber tow. The filter member or at least one of the filter members (eg, terminal filter member and/or upstream filter member) may include activated carbon. The filter member or at least one of the filter members (eg, terminal filter member and/or upstream filter member) may comprise paper. The filter member or at least one of the filter members (eg, terminal filter member and/or upstream filter member) may include plant material, such as extruded plant material. The or each filter element may be enclosed by a plug (eg, paper plug).

The or each filter member may have a substantially cylindrical shape, with a diameter that substantially matches the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The or each filter member may have an axial length of less than 20 mm, such as between 8 and 15 mm, such as between 9 and 13 mm, such as between 10 and 12 mm.

The filter member or at least one of the filter members may be a solid filter member. The filter member or at least one of the filter members may be a hollow pore filter member. The hollow pore filter or each hollow pore filter member may have a pore diameter of between 1 and 5 mm (eg between 2 and 4 mm or between 2 and 3 mm).

The terminal filter member (located at the downstream end of the consumable) may be joined to the upstream member forming the consumable by a surrounding binding layer (eg, a layer of binding paper). The tipping paper may have an axial length that is greater than the axial length of the terminal filtration member such that the tipping paper completely surrounds the terminal filtration member plus the wrapping around any adjacent upstream members.

The filter member or at least one of the filter members (eg a terminal filter member) may comprise a capsule (eg a crushable capsule (crush ball)) containing a liquid flavoring (eg as listed above any of the seasonings). The capsules can be crushed by the user during smoking of the consumable to release the flavoring. The capsule may be located at the axial center of the terminal filter member.

In some embodiments, the consumable may include an aerosol cooling member adapted to cool aerosol generated by the aerosol-forming substrate (generated by heat exchange) prior to inhalation by the user.

The smoke cooling member will be located downstream of the smoke forming substrate. For example, it may be located between the aerosol-forming substrate and the filter member and/or between two filter members. The smoke cooling member may be at least partially (eg completely) surrounded by a (paper) wrapping layer.

The smoke cooling member may be formed from a plastic material selected from the group consisting of: polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE), polyethylene terephthalate (PET) ). The smoke cooling member may be formed from sheets of rolled/gathered material to form A structure with high surface area and multiple longitudinal channels to maximize heat exchange and cooling of the smoke.

The consumable may include a spacing member defining a space or cavity between the aerosol-forming substrate and the downstream end of the consumable. The spacing member may comprise a cardboard tube. The spacing member may be at least partially (eg completely) enclosed by the (paper) wrapping layer.

The spacing member may have an outer diameter of between 5 and 10 mm, such as between 6 and 9 mm or between 6 and 8 mm, such as about 7 mm. It may have an axial length of between 10 and 15 mm, such as between 12 and 14 mm or 13 and 14 mm, such as about 14 mm.

In a second aspect, an HNB consumable formed by the method of the first aspect is provided.

In a third aspect, a smoking alternative system is provided, the smoking alternative system including the HNB consumable as described in the second aspect, and a device including a heating member.

The device may be a HNB device, ie a device adapted to heat but not ignite the smoke-forming substrate.

The device may include a body for housing the heating member. The heating member may include an elongated (eg, rod-shaped, tube-shaped, or blade-shaped) heating member. The heating member may project into or surround the cavity within the body for receiving the consumables described above.

The device (eg the body) may further comprise a power source (eg a (rechargeable) battery) for powering the heating member. It may further include a control unit to control the power supply to the heating member.

In a fourth aspect, a method of using the smoking alternative system as described in the third aspect is included, the method comprising the steps of: inserting the HNB consumable into the device; and using the heating member to heat the HNB Supplies.

In some embodiments, the method includes the steps of inserting the HNB consumable into the cavity within the body, and penetrating the HNB consumable with a heating member while inserting the HNB consumable. For example, the heating member may penetrate the aerosol-forming substrate in the HNB consumable.

The skilled person will understand that, except where mutually exclusive, features or parameters described with respect to any one of the above aspects may be applied to any other aspect. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied in any aspect and/or combined with any other feature or parameter described herein.

1:HNB consumables

2:Smoke forming substrate

3: Wrapping layer

4: Upstream filtering components

5: Downstream (terminal) filtering components

6: Cardboard tube spacers

7: Connecting layer

8:Capsule

9: Annular gap

10:HNB equipment

11:Cavity

12:Subject

101: Steps

102: Steps

103: Steps

104:Step

105: Steps

106: Steps

107: Steps

108: Steps

109: Steps

1': consumables

1": Consumables

Embodiments illustrating the principles of the invention will now be discussed in more detail, enabling an understanding of the invention, and enabling understanding of additional aspects and features of the invention, with reference to the accompanying drawings, in which: FIG. The first embodiment of the HNB consumable formed by the method; Figure 2 shows the second embodiment of the HNB consumable formed by the method; Figure 3 shows the third embodiment of the HNB consumable formed by the method; and Figure 4 shows A first embodiment within the equipment forming the HNB system is presented.

Figure 5 shows an illustrative diagram of an embodiment of the method.

As shown in FIG. 1 , the HNB consumable 1 includes an aerosol-forming substrate 2 at the upstream end of the consumable 1 .

The aerosol-forming substrate 2 includes recombinant tobacco that includes nicotine as a volatile compound and is added with up to 20% by weight of flavorings selected from the group consisting of menthol, peppermint, spearmint, licorice, chocolate, fruit flavors, Vanilla, spice, coffee, eucalyptus, and tobacco flavors.

The aerosol forming substrate 2 comprised 65 weight percent tobacco provided in the form of aggregated chips produced from slurry tobacco sheets. Tobacco is added with 20% by weight of humectant (e.g. Such as propylene glycol (PG) or vegetable glycerin (VG)) and have a moisture content between 7-9 weight percent. The aerosol-forming substrate also includes cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 is formed in a substantially cylindrical shape so that the consumable resembles a conventional cigarette. It has a diameter of approximately 7 mm and an axial length of approximately 12 mm.

The aerosol-generating substrate 2 is surrounded by a paper wrapping layer 3 .

The consumable 1 includes an upstream filter member 4 and a downstream (terminal) filter member 5 . The two filter elements 4, 5 are separated by a cardboard tube spacer 6. The two filter elements 4, 5 are formed from cellulose acetate fiber bundles and are wrapped with corresponding paper plug layers (not shown).

Both filter members have a substantially cylindrical shape. The diameter of the upstream filter member 4 matches the diameter of the aerosol forming substrate 2 . The diameter of the terminal filter member 5 is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 and wrapping layer 3 . The axial length of the upstream filter member 4 is slightly shorter than that of the terminal filter member 5 and is 10 mm compared to 12 mm of the terminal filter member 5 .

The cardboard tube spacers are longer than each of the two filter sections and have an axial length of approximately 14 mm.

Each filter element 4,5 is a hollow pore filter element having a hollow, longitudinally extending pore cavity. The diameter of the cavities in the upstream filter member 4 is slightly larger than the diameter of the cavities in the final filter member 5 and has a diameter of 3 mm compared to the 2 mm of the final filter member 5 .

The cardboard tube spacer 6 and the upstream filter section 4 are surrounded by the wrapping layer 3 .

The final filter element 5 is joined to the upstream element forming the consumable by means of a surrounding paper binding layer 7 . The tipping layer 7 surrounds the terminal filter section and has an axial length of approximately 20 mm so that it covers part of the cardboard tube spacer 6 .

Figure 2 shows a second embodiment of a consumable 1', which is the same as that shown in Figure 1, except that the final filter element 5 comprises a crushable capsule 8 (crushing ball) which broken The capsules hold liquid menthol or cherry or vanilla flavorings. The capsule 8 is spherical and has a diameter of 3.5 mm. It is positioned in the axial center of the terminal filter section 5 .

Figure 3 shows a third embodiment of the consumable 1", which is the same as the first embodiment, except for the following conditions: the wrapping layer 3 does not completely surround the cardboard tube spacer 6, so that between the connecting layer 7 and the wrapping layer 3 There is an annular gap 9 between the cardboard tube spacers 6 downstream of the ends.

Figure 4 shows a first embodiment inserted into a HNB device 10, which HNB device includes a rod-shaped heating member (not shown). The heating member projects into a cavity 11 within the body 12 of the device.

The consumable 1 is inserted into the cavity 11 of the body 12 of the device 10 so that the heating rod penetrates the aerosol-forming substrate 2 . Heating of the reconstituted tobacco in the aerosol-forming substrate 2 is achieved by energizing the heating means, for example with a rechargeable battery (not shown). As the tobacco heats, moisture and volatile compounds (such as nicotine) within the tobacco and aerosol former are released as vapor and become entrained in the air flow produced by the inhalation by the user at the terminal filter section 5 .

As the vapor cools within the upstream filter member 4 and cardboard tube spacer 6, it condenses to form a smoke containing volatile compounds for inhalation by the user.

Figure 5 shows an illustrative diagram of an embodiment of a manufacturing method. Tobacco is ground to reduce particle size to less than 120 microns101.

Ground tobacco 101 is then combined with guar gum binder, cellulose pulp filler, propylene glycol, and vegetable glycerin to form mixture 102.

Mixture 102 is combined with an aqueous medium to form slurry 103 . Mixing of the mixture 102 with the aqueous medium is accomplished in a high shear mixer. The tobacco content of the slurry is from about 50 to 90% of the total solids content of the slurry, with the total solids content being from 15 to 30 weight percent of the slurry.

The flavoring contained in the propylene glycol or vegetable glycerin base liquid (where the flavoring content is in the range of 1 to 50 weight percent based on the total weight of flavoring and base liquid) is combined 104 with the slurry.

The resulting slurry is cast onto a dryer belt to form sheet 105. The sheet is dried using a vapor drying device to remove excess moisture content from the sheet until the sheet is self-supporting 106 .

The sheet is wound onto tube 107 for storage. The moisture content of the cast sheet when wound is about 7 to 15 percent of the dry weight of the tobacco sheet.

The sheet may then be made into all or part of an HNB consumable 108 suitable for HNB equipment. This is accomplished by cutting the sheet to the appropriate size. The sheet may be used as all or part of the HNB consumables 109 for the HNB device. In detail, it is a slurry type reconstituted tobacco product used in HNB equipment.

The features disclosed in the foregoing description, or in the following claims, or in the drawings may be used individually or in any combination of such features to implement the invention in its various forms, as the case may be. Expressed in their specific form or in terms of means for performing a disclosed function, or a method or process for obtaining a disclosed result.

While the present invention has been described in connection with the above-described exemplary embodiments, many equivalent variations and modifications will be apparent to those skilled in the art given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are to be regarded as illustrative and not restrictive. Various changes to the described embodiments may be made without departing from the scope of the invention.

For the avoidance of any doubt, any theoretical explanations provided in this article are provided for the purpose of improving the reader's understanding. The inventors do not wish to be bound by any of these theoretical explanations.

Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

Throughout this specification (including the claims below), the words "have," "includes," and "includes," and variations thereof will be understood to imply inclusion unless the context requires otherwise. A stated integer or step, or group of integers or steps, does not exclude any other integer or step, or group of integers or steps.

It must be noted that, as used in this specification and the accompanying claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from "about" one particular value and/or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when a value is expressed as an approximation by use of the antecedent "about," it will be understood that the particular value forms another embodiment. The word "about" with respect to a numerical value is optional and means, for example, +/-10%.

The words "preferred" and "preferably" are used herein to refer to embodiments of the invention that may provide certain benefits under certain circumstances. However, it is to be understood that other embodiments may be preferred under the same or different circumstances. Therefore, recitation of one or more preferred embodiments does not mean or imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the present disclosure or from the scope of the claims.

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Claims (12)

A method for manufacturing a heat-not-burn (HNB) consumable including an aerosol-forming substrate, wherein the aerosol-forming substrate is a slurry type of recombinant plant material, the method includes the following steps: grinding a ground plant material Combine with an aqueous medium to form a slurry; provide a flavoring in a base liquid to the slurry; cast the slurry to form a sheet; dry the sheet to form an aerosol-forming substrate ; and incorporating a portion of the aerosol-forming substrate into an HNB consumable, wherein the base liquid is a polyol. The method of claim 1, wherein the flavoring is selected from the group consisting of menthol, peppermint, spearmint, licorice, chocolate, fruit flavor, vanilla, spice, coffee, eucalyptus, and tobacco flavor. The method of claim 2, wherein the flavoring is a non-tobacco flavoring. The method of claim 2, wherein the flavoring is synthetically derived menthol. A method as claimed in claim 1, wherein the flavoring is provided in an amount resulting in a level of up to 20 weight percent of the dried aerosol forming substrate. The method of claim 1, wherein the plant material is tobacco. The method of any one of claims 1 to 6, wherein the seasoning content of the seasoning in the base liquid is 1 to 15 weight percent based on the total weight of the seasoning and the base liquid. An HNB consumable formed by the method of any one of claims 1 to 7. A system includes the HNB consumable as claimed in claim 8, and a device including a heating component. The system of claim 9, wherein the device includes a body for receiving the heating member, and the heating member includes an elongated heating member. A method of using the system of claim 9 or 10, the method comprising the steps of: inserting the HNB consumable into the device; and using the heating member to heat the HNB consumable. The method according to claim 11, including the following steps: inserting the HNB consumable material into a cavity in a main body of the device, and using the heating member to penetrate the HNB consumable material when inserting the HNB consumable material.