US20240041092A1

US20240041092A1 - Aerosol generating material

Info

Publication number: US20240041092A1
Application number: US18/256,774
Authority: US
Inventors: Pablo Javier BALLESTEROS GOMEZ; Brandhika RIKO VINERSIANO; Bayu YODHANA PUTRA; Mohammad NOVAN HIDAYAT; Tanti KARTIKA DEWI
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2020-12-11
Filing date: 2021-12-13
Publication date: 2024-02-08
Also published as: JP2023552301A; GB202019625D0; EP4258905A1; CA3199399A1; AU2021397878A1; WO2022123276A1; AU2021397878A9

Abstract

The invention relates to an aerosol generating material comprising cut tobacco material and cut plant material, the cut plant material having an average particle size of at least about 0.25 mm. The invention further relates to non-combustible aerosol provision systems and consumables comprising the aerosol generating material, as well as to methods for preparing the aerosol generating material.

Description

PRIORITY CLAIM

The present application is a National Phase entry of PCT Application No. PCT/GB2021/053267, filed Dec. 13, 2021, which claims priority from GB Application No. 2019625.9, filed Dec. 11, 2020, each of which is hereby fully incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to an aerosol generating material comprising tobacco material and particles of plant material.

BACKGROUND

Aerosol-generating materials for use in a combustible or a non-combustible aerosol provision system may include a variety of different active substances and/or flavors and a user selects aerosol-generating material to provide the desired user experience.
The inclusion of clove material into conventional combustible cigarettes is known in the art that and is commonly known as kretek. A factory made kretek cigarette has several features which can impact the organoleptic properties of the aerosol generated. It may include a sweetened tipping, which can amplify and balance the taste, the casing and flavor add a unique, sweet and spicy flavor. The tobacco comprises chopped “Rajangan” tobacco which also adds to the distinctive taste of these products. A variety of types of tobacco may be included in the kretek cigarette, for example, “dark Rajangan” tobacco has a complex taste, compared to “bright Rajangan” tobacco which is known for its' lighter taste. The cut clove found in these cigarettes contributes to a spicy, aromatic numbing and crackling flavor. These smoking articles may contain additional flavor components.

SUMMARY

In accordance with a first aspect of the invention described herein, there is provided an aerosol generating material comprising cut tobacco material and cut plant material, the cut plant material having an average particle size of at least about 0.25 mm.
In some embodiments, the cut plant material has an average particle size of from about 0.3 mm to about 0.5 mm.
In some embodiments, the cut plant material comprises clove.
In some embodiments, the cut tobacco material comprises reconstituted tobacco.
In some embodiments, comprising from about 25% to about 40% by weight of cut plant material based upon the weight of the aerosol generating material.
In some embodiments, the density of the aerosol generating material is from about 0.25 to about 0.45 g/cm³, and optionally from about 0.3 to about 0.4 g/cm³.
In some embodiments, the cut tobacco material has a cut size of from 20 to 25 CPI (cuts per inch), or from about 7.9 to about 9.8 cuts per cm.
In some embodiments, the aerosol generating material has a water content of from about 8 to about 9%.
In some embodiments, the cut plant material is not immobilised within the aerosol generating material.
In some embodiments, the cut plant material is not incorporated into tobacco material.
In some embodiments, the aerosol generating material does not include a binder to bond the cut tobacco material and cut plant material.
According to a second aspect of the invention, there is provided a non-combustible aerosol provision system comprising an aerosol generating material according to the first embodiment.
In some embodiments, the system is an aerosol generating material heating system comprising an aerosol generating material which is to be heated to volatilise constituents, and optionally including a filter or filter element.
In some embodiments, the system is a hybrid system comprising an aerosol generating material which is to be heated to volatilise constituents, and a liquid which is to be heated to form a vapor, and optionally including a filter or filter element.
In some embodiments, the aerosol generating material is heated by the vapor.
In some embodiments, the liquid is a nicotine-free liquid.
In some embodiments, the system includes a means for heating the liquid to form a vapor, but does not include a separate means for heating the aerosol generating material.
According to a third aspect of the present invention, there is provided a consumable comprising an aerosol generating material according to the first aspect.
In some embodiments, the consumable comprises a cartridge or pod comprising the aerosol generating material.
In some embodiments, the consumable comprises a rod or stick comprising the aerosol generating material.
According to a fourth aspect of the invention, there is provided a method of preparing an aerosol generating material according to the first aspect, comprising combining cut tobacco material and cut plant material.
In some embodiments, the consumable comprises the cut tobacco material and cut plant material are combined by simple blending.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to accompanying drawing, in which

FIG. 1 is a flow chart showing key steps of a process according to embodiments of the present invention;

FIG. 2 is a schematic cross-sectional view of a product for heating aerosol generating material to volatilise at least one component of the aerosol generating material; and

FIG. 3 is a schematic view of a hybrid system for heating aerosol generating material to volatilise at least one component of the aerosol generating material.

DETAILED DESCRIPTION

The aerosol-generating material described herein is to be used to generate an aerosol with distinctive flavor and qualities to be inhaled by the end user. One of the aims of this invention is provide the end user with an experience of using a non-combustible aerosol provision system that is distinctive as a result of the inclusion of the plant material. The impact of the plant material is influenced by the form in which it is included in the aerosol generating material and how that affects the aerosol generated.
In embodiments where the plant material is clove, the aerosol generating material provides an aerosol generated by a non-combustible aerosol provision system that is more closely aligned with the experience of consuming a combustible kretek cigarette.
The present invention relates to an aerosol generating material comprising a cut tobacco material and a cut plant material. The aerosol generating material may be used in a non-combustible aerosol provision system, for example by incorporation into a consumable. The cut plant material has an average particle size of at least about 250 μm, and optionally up to about 500 μm or from about 280 μm to about 450 μm.
Particles of these dimensions have been found to provide sensory properties to the generated aerosol that differ to those provided by finer plant particles (such as what is sometimes referred to as “dust”). For example, when the plant material is clove, the sensory properties of the aerosol are more like the distinctive taste characteristic of clove and kretek cigarettes.
The inclusion of cut plant material with this larger particle size also means that it is easier to incorporate a large proportion of plant material into the aerosol generating material. For example, in some embodiments, the aerosol generating material comprises as much as about 35% by weight plant material. If the plant particles were very fine, this could require the particles to be immobilised within the aerosol generating material to prevent the plant material being lost or moving relative to the cut tobacco material so that the materials are no uniformly or homogenously mixed.
The presence of such a high proportion of fine plant particles would also increase the density of the aerosol generating material within the non-combustible aerosol provision system or consumable and could make it harder for an air flow, aerosol or vapor to pass through it, or for all of the aerosol generating material to be uniformly exposed to heat to generate an aerosol. As a rule, the smaller the particle size, the greater the surface area and therefor the greater the flavour delivery. However, smaller particle size can lead to processing difficulties and it can be harder to retain the particles within the aerosol generating material and/or consumable or non-combustible aerosol provision system.
The invention enjoys advantages such as improved flavor of the aerosol generated by the aerosol generating material by combining a cut botanical material with a cut tobacco material. The size of the cut botanical material has several advantages detailed herein.
The aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, comprise one or more active substances and/or flavors, one or more aerosol-former materials, and optionally one or more other functional material.
The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.
In some embodiments, the aerosol generating material is a simple mixture or blend of the cut tobacco material and the cut plant material.
The Plant Material
As used herein, the cut plant material may be clove or other material derived from a plant.
As noted herein, the cut plant material may be derived from any material derived from plants including, but not limited to, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. The material may be in the form of particles, granules, pellets, shreds, strips, sheets, or the like. Example plants or botanicals are tobacco, Eucalyptus, star anise, hemp, cocoa, Cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, Ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, Papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, Curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, Carvi, Verbena, tarragon, geranium, mulberry, Ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.
In some embodiments, the cut plant material is clove. The use of cloves as the cut plant material provides a distinctive flavor and sensorial experience for the end user. Cloves are known to have sensory effects including aroma, spicy, numbing, crackling, and throat soothing features among others. The organoleptic properties of the inhaled medium is thereby improved, and this can also be achieved without changing the dimensions of the non-combustible aerosol provision system.
The use of cloves in combustible cigarettes also has a historic precedent in some regions, known as a “kretek” cigarette. The invention provides the user with the experience of a kretek cigarette with non-combustible aerosol generating devices. The use of cloves therefore add value to a traditionally tobacco flavored non-combustible aerosol generating devices. In some embodiments, the aerosol generated has flavours that are reminiscent of kretek cigarettes, which is advantageous as this flavor is particularly popular with consumers in certain regions, for example Indonesia. Cloves contain several essential oils, for example eugenol, which is known to provide some of the characteristic taste of the clove and is considered to have an analgesic effect in traditional Chinese medicine.
The clove material may be derived from whole cloves or from parts of whole cloves, clove stalks, mother clove, blown cloves and/or exhausted cloves as well as other clove derivatives that are known in the art or a mixture of these.
In some embodiments, the plant material is cut into particles. For example, the plant material may be cut using any suitable process.
In some embodiments, the preparation of the cut plant (e.g. clove) particles involves the following steps:

- 1) Conditioning the plant material with water, steam and temperature, to increase the moisture content from 10% to about 30%.
- 2) Cutting the plant material, for example using a machine with rotatory knives, where the rate at which the plant material is fed into the machine and the speed of the rotary cutting controls the cut length.
- 3) The particle size of the cut plant material may be determined by off line testing (sieving).

In some embodiments, the plant particle size may range from about 0.2 to 0.5 mm, 0.25 to 0.4 mm, or 0.3 to 0.5 mm, or from about 0.25 to about 0.45 mm.
In some embodiments, the plant material is cut to a size of 60-90 CPI (cuts per inch) or 23.6 to 35.4 cuts per cm, resulting in particles with an average size of from about 0.42 to about 0.28 mm.
The particle size can be measured in a variety of ways, such as laser diffraction, microscopy, or preferentially by sieving. A common practice is to give cut material a “mesh value”, which reflects the ability of more than 95% of the particles of a given particle population to pass through a screen of a given mesh value. In that connection, mesh values reflect the number of mesh holes for each inch of screen. This method selects particles of the desired size without the requirement to measure multiple particles and measure an average distribution. Additionally, this may be used to measure the size of particles which do not have a regular spherical shape, making mean measurements challenging.
The size of the cut plant material particles is important and has an effect on a number of features of the blend, such as improved mixing of the blend components and flavor release/delivery. The particle size is selected to deliver a suitable sensory effect, and the clove is selected to deliver a characteristic taste. Without wishing to be bound by any one particular theory, it is speculated that the chopping of the plant material to form the cut plant material particles enhances the release of flavor constituents including volatile flavors and aromatic constituents. The increased surface area of the tobacco particles is also thought to aid volatilisation, as described herein.
Particle size is important as this alters the surface area to volume ratio of the particles. Without wishing to be bound by theory, it is proposed that larger particles with lower surface area to volume ratios have a lower exposure to the air, and this reduces evaporation of volatile compounds that contribute to the distinctive flavor of the aerosol generated. Larger particles are easier to handle, may be stored for longer and there is less release of volatile compounds prior to intentional heating by the end user.
A smaller particle size of the cut plant material is associated with lower particle size distribution and fill value. This makes the material easier to spread throughout an aerosol generating material uniformly. This provides a consistent taste for the end user throughout usage of the aerosol generating material.
On the other hand, a larger particle size of the cut plant material may be associated with a different sensorial experience, and the particles must be large enough to for the volatiles to escape upon heating without being too densely packed to impede this.
Larger particles are easier to handle, and remain substantially dry, without substantial destruction of the cell structure. Less sophisticated machinery can be used and this may be more economical to manufacture. As less grounding is required, this is less energy intensive, and save energy and time in the manufacturing process.
Plant material particles of the desired size may be formed by grinding, shredding, cutting or crushing the plant material. Suitable machinery to create such plant particles includes, for example, shredders, cutters, or mills, such as hammer mills, roller mills or other types of commercially available milling machinery. The size of the plant particles is selected to provide particles which can be readily prepared from a variety of different types of plant material including cloves and having the properties described herein, and which provide a source of volatile compounds that are readily released.
According to some embodiments, the plant material, is prepared along the following lines. First, the plant material is conditioned to adjust (increase) the water content, for example to within the range of about 32% to about 36%. This may be done whilst exposing the plant material to a temperature of from about 60 to about 70° C. and to water and steam. The plant material may then undergo a bulking step, for example for a period of 2 hours, to ensure that the water applied during the conditioning step is well absorbed by the plant material. Following bulking, the plant material may be ready to be cut to the desired particle size. Thereafter, the cut plant material may undergo a drying step to adjust (reduce) the water content, for example to within the range of about 11% to about 12%. This may be done whilst exposing the plant material to a temperature of from about 45 to about 55° C.
The Tobacco
The tobacco material used to form the cut tobacco material may be any type of tobacco and any part of the tobacco plant, including tobacco lamina, stem, stalk, ribs, scraps and shorts or mixtures of two or more thereof. Suitable tobacco materials include the following types: dark tobacco, light tobacco, Rajangan tobacco, Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials, optionally including those listed here. Some of these tobacco varieties, such as Rajangan tobacco, may be processed differently, as known to the skilled person.
The tobacco may be expanded, such as dry-ice expanded tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material may be reconstituted tobacco material. The tobacco may be pre-processed or unprocessed, and may be, for instance, solid stems (SS); shredded dried stems (SDS); steam treated stems (STS); or any combination thereof. The tobacco material may be fermented, cured, uncured, toasted, or otherwise pre-treated.
In some embodiments, the tobacco material is in the form of reconstituted tobacco that has been processed and cut to form a cut rag tobacco.
In some embodiments, the tobacco material is in the form of tobacco particles.
In some embodiments, the tobacco material may undergo treatment steps in order to improve its properties for inclusion in an aerosol generating material. Illustrative steps are shown in the flow chart of FIG. 1 .
In some embodiments, the tobacco material has been conditioned. For example, this may involve adjusting the water content of the starting tobacco material to 20-22%. In some embodiments, casing may be added to the tobacco material, for example in a ratio of 1.8 to 18% by weight.
The tobacco material may also, in some embodiments, undergoing a bulking step.
Following any such pre-treatment steps, the tobacco material is cut. In some embodiments, the cut size is selected to ensure that the cut tobacco material and the cut plant material have particle sizes that produce a blend with desirable properties, as discussed herein. In some embodiments, the tobacco material is cut to a size of 20-25 CPI (cuts per inch) or from about 7.9 to about 9.8 cuts per cm, resulting in strips with an average width of 1 to 1.5 mm.
In some embodiments, the cut tobacco is dried. For example, the drying of the tobacco may reduce the water content to about 7 to 8%.
In some embodiments, one or more flavors may be added to the tobacco material. This may be done at any stage of the tobacco processing. In some embodiments, the flavor is added after the tobacco material is cut and after any further drying step.
In some embodiments, a flavor is added to the tobacco material in an amount of from about 1% to about 3%, or from about 1 to about 2% by weight.
As used herein, the terms “flavor” and “flavorant” refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavor materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, Cannabis, licorice (liquorice), Hydrangea, eugenol, Japanese white bark Magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, Papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, Cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, Eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, Ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, Curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, Carvi, Verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.
In some embodiments, the flavor comprises menthol, spearmint and/or peppermint. In some embodiments, the flavor comprises flavor components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavour components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from Cannabis.
In some embodiments, the flavor may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect.
A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.
In some embodiments, flavors are included that provide the aerosol generated by the aerosol-generating material with aroma and taste reminiscent of a kretek product. In some embodiments, flavors maybe be added to emphasize certain flavor notes or sensual effects associated with a kretek product. In some embodiments of the invention, this flavor is eugenol.
In some embodiments, flavors are included to generate extra connotations of sweetness and fruits and/or tropical notes.
The Mixture of Plant Material and Tobacco Material
The aerosol generating material may be prepared by simple mixing of one or more cut plant materials and one or more cut tobacco materials. The mixing may involve blending of the cut materials, for example, using conventional mixing or blending techniques used to mix or blend cut tobacco material. Alternatively, the cut plant material may be added over the cut tobacco.
In some embodiments, the cut plant material is in the form of a free-flowing solid when it is mixed or blended with the cut tobacco material.
In some embodiments, no binder is used when the tobacco and cut plant material, such as clove, is mixed.
The mixing can take place, for example, in a rotatory cylinder mixer, with the selection of appropriate process parameters including: cylinder length, inclination of the cylinder, and residence time. Generally, the longer the residence time, the greater the mixing of the materials.
In some embodiments, the particles of the cut tobacco material and the cut botanical material are differently sized. In some embodiments, the particles of the cut tobacco material and the cut botanical material are the same size. The choice of size depends on several factors, such as taste and mouth-feel of the generated aerosol, packed density of the aerosol generating material and other factors known to the person skilled in the art.
The amount of the cut plant material included in the aerosol generating material and the ratio of plant material to cut tobacco material can vary in different embodiments. For example, in some embodiments, a stronger clove flavor can be provided with a higher proportion of clove material. This applies to other plant materials and flavors. On the other hand, increasing the tobacco proportion in the aerosol generating material may increase the tobacco flavor and/or nicotine content in the aerosol generated. The proportion of ingredients can also affect the mouth-feel and texture of the aerosol.
The selection of the amount of plant material to include in the aerosol generating material will be based upon sensorial considerations. The aim is add the flavor and aroma of the plant material and to do so in appropriate balance with the delivery of tobacco flavors and aromas. It may also be a consideration that the flavor delivery should last for the entirety of the period of use of the aerosol generating material
In some embodiments, including embodiments where the plant material is clove, at least 15% by weight of the aerosol generating material is plant material. The upper limit may be about 35% by weight of the aerosol generating material being the plant material.
Varying the proportion of the components can also change the density of the aerosol generating material and the amount that may be packed into a container or consumable of given dimensions. An additional factor to take into consideration is the price of the component materials. The blend can be formulated to provide a cost effective product. The inclusion of a higher proportion of cloves can help with mixing between the clove material and the tobacco material.
In some embodiments, the blend of cut tobacco material and cut plant material includes at least about 5% by weight or volume of the cut plant material and may include between about 25% to about 40% by weight or volume of the cut plant material. In some embodiments, the weight and/or volume of the clove component with respect to the tobacco material component is about 25%. In some embodiments, the blend of cut tobacco material and cut plant material includes 5, 10, 15, 20, 25, 30, 35, 40 or 45% by weight or volume.
In some embodiments, the aerosol generating material further comprises a diluent. The diluent may be in solid or liquid form. In some embodiments, the diluent is inert or substantially inert.
In some embodiments, the aerosol generating material further comprises at least one aerosol forming agent which may be, for instance, a polyol aerosol generator or a non-polyol aerosol generator, preferably a non-polyol aerosol generator. It may be a solid or liquid at room temperature, but preferably is a liquid at room temperature. Suitable polyols include sorbitol, glycerol, and glycols like propylene glycol or triethylene glycol. Suitable non-polyols include monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, and esters such as diacetin, triacetin, triethyl citrate or isopropyl myristate. A combination of aerosol forming agents may be used, in equal or differing proportions. Glycerol and propylene glycol may be particularly preferred.
In some embodiments, the aerosol generating material includes one or more additional components, some of which may immobilise the cut plant material and/or the cut tobacco material. The aerosol generating material or the tobacco material may comprise one or more binding additives. The binding additive helps to adhere particles of tobacco material to each other and to other components in the aerosol generating material. Suitable binding additives include, for example, thermoreversible gelling agents such as gelatin, starches, polysaccharides, pectins, alginates, wood pulp, celluloses, and cellulose derivatives such as carboxymethylcellulose. Inclusion of a binding additive may have the advantage that the aerosol-generating material is easier to handle and process.
In some embodiments, the aerosol generating material does not include a binder, plasticizer or gelling agent. This reduces material costs and simplifies manufacturing. Additionally, the inclusion of a binder may, for some plant materials such as clove, require modification of the plant material by either temperature treatment or by water/steam treatment, which can remove some of the oils that generate the desired sensorial effect.
In some embodiments, the aerosol generating material further comprises a preservative. Suitable preservatives would be readily known to the skilled person and would include, for example, those that are safe for use in products producing inhalable aerosols. Examples of preservatives that might be used include: propylene glycol, carvacrol, thymol, L-menthol, 1,8-cineole, phenoxyethanol, PhytoCide, sorbic acid and its salts, sodium hydroxymethylglycinate, ethylhexylglycerin, parabens and vitamins such as vitamin E or vitamin C.
According to another aspect of the present invention, there is provided a non-combustible aerosol provision system including an aerosol generating material. The aerosol generating material included in the aerosol provision system may comprise, consist essentially of, or consist of the aerosol generating material as described herein.
As used herein, an aerosol provision system includes non-combustible aerosol provision systems that release compounds from an aerosol generating material without combusting the aerosol-generating material, such as tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.
According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user. In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.
In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.
In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.
In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.
Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.
In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.
In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.
In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.
In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.
According to some embodiments, the aerosol generating material is included in the aerosol provision system to volatilise components of the aerosol generating material by heating but not combusting the material (i.e., a tobacco heating product or so-called Heat-not-Burn product). In some of these products, the aerosol generating material is heated to generate an aerosol.
FIG. 2 shows a cross-sectional view of an example of a tobacco heating product for heating an aerosol generating material. The apparatus 11 has a heating chamber 14 which in use contains the aerosol generating material to be heated and volatilised. In this embodiment, the aerosol generating material is in the form of a monolithic nicotine delivery composition 13. The aerosol generating material could however be multiple particles of aerosol generating material held in the heating chamber or provided in a cartridge.
The apparatus 11 of FIG. 2 further has an electronics/power chamber 16 which may, for example, contain electrical control circuitry and/or a power source (not shown). The electrical control circuitry may include a controller, such as a microprocessor arrangement, configured and arranged to control the heating of the aerosol generating material via a heating element (not shown). The electrical control circuitry may in use receive a signal from for example a puff-actuated sensor which is sensitive to for example changes in pressure or changes in rate of air flow that occur upon initiation of a draw on the apparatus 11 by a user. The electrical control circuitry can then operate so as to cause heating of the aerosol generating material “on demand”. Various arrangements for a puff-actuated sensor are available, including for example a thermistor, an electro-mechanical device, a mechanical device, an optical device, an opto-mechanical device and a micro electro mechanical systems (MEMS) based sensor. As an alternative, the apparatus may have a manually operable switch for a user to initiate a puff.
The heating chamber 14 is contained within the housing 12. There may be a support and/or insulating means (not shown) positioned between the heating chamber 14 and the housing 12, for example to assist in heat-insulating the housing 12 from the heating chamber 14, so that the housing 12 does not become hot or at least too hot to touch during use.
The housing 12 includes an inlet 15 through which air is drawn into the apparatus. The housing 12 also includes an outlet 17 at a mouthpiece 18 of the apparatus 11. Air is drawn into the apparatus 11 through the inlet 15, travels through the apparatus picking up the active substance and other volatile constituents released by the aerosol generating material 13, and the resulting aerosol generated by the apparatus 11 leaves the apparatus 11 through the outlet 19 and is inhaled by the user.
According to some embodiments, the aerosol generating material is included in a so-called hybrid system for heating aerosol generating material to volatilise at least one component of an aerosol generating material. In some of these products, the aerosol generating material is heated to generate an aerosol, in addition to the heating of a liquid, such as a nicotine-containing liquid or a nicotine-free liquid, which is heated by a heat source to form an aerosol or vapor. In some hybrid systems, the aerosol or vapor formed from the liquid is drawn over or through the aerosol generating material, picking up the active substance(s) and other volatilised components. In other embodiments, the aerosol or vapor formed from the liquid is not drawn over or through the aerosol generating material.
FIG. 3 shows a cross-sectional view of an example of a hybrid product for heating an aerosol generating material and a liquid. The apparatus 21 has a housing 22 containing a chamber 24 which in use contains the aerosol generating material 23 to be heated and volatilised. The aerosol generating material could be held in the chamber or provided in a cartridge. The housing 22 also contains a liquid reservoir 25 containing a liquid 26 to be heated to form a vapor.
The apparatus 21 further has an electronics/power chamber 27 which may, for example, contain electrical control circuitry and/or a power source (not shown). The electrical control circuitry may include a controller, such as a microprocessor arrangement, configured and arranged to control the heating of the aerosol generating material and of the liquid 26 via one or more heating elements (not shown). The electrical control circuitry may allow the apparatus 21 to be puff-actuated, so as to cause heating of the aerosol generating material “on demand”. As an alternative, the apparatus 22 may have a manually operable switch for a user to initiate a puff.
The housing 22 also includes an inlet 28 through which air is drawn into the apparatus. The housing 22 also includes an outlet 29 at a mouthpiece 30 of the apparatus 21. Air is drawn into the apparatus 21 through the inlet 28, travels through the apparatus picking up the vapor created by heating the liquid 26 in the liquid reservoir 25, and active substance(s) and volatile component released by the aerosol generating material 23, and the resulting aerosol generated by the apparatus 21 leaves the apparatus 21 through the outlet 29 and is inhaled by the user.
The hybrid device 21 shown schematically in FIG. 3 represents just one possible configuration of such an apparatus. The relative positions of the liquid reservoir 25 and the aerosol generating material chamber 24 can be changed, as can the path of the air flowing through the apparatus.
In one embodiment, the liquid reservoir is positioned upstream of the aerosol generating material to be volatilised. Alternatively, the liquid reservoir may be positioned downstream of the aerosol generating material to be volatilised. In a yet further arrangement, the two sources of aerosol in the apparatus may be arranged side-by-side, etc.
In some embodiments, the vapor produced by heating the liquid in the liquid reservoir flows over or through the aerosol generating material comprising or consisting of one or more aerosol generating material. In some embodiments, the elevated temperature of the vapor causes the active substance and volatile components to be released. Alternatively or in addition, the aerosol generating material may be separately heated by a heating means.
In some embodiments, a hybrid device is provided in which the vapor created by heating a liquid heats the aerosol generating material in order to volatilise at least one component of the aerosol generating material. In some embodiments, the liquid is a nicotine-free liquid. In other embodiments, the liquid contains nicotine. Where the aerosol generating material is heated by the vapor to volatilise at least one component of the aerosol generating material, in certain embodiments the device does not include a separate means for heating the aerosol generating material.
In other embodiments, the vapor produced by heating the liquid in the liquid reservoir does not flows over or through the aerosol generating material. Rather, this vapor and the aerosol generated by heating the aerosol generating material only mix after they are both formed.
The tobacco heating products and hybrid products described herein may, in some embodiments, include aerosol generating material in the form of containers or cartridges containing the aerosol generating material. These containers or cartridges may be removable. They may replace both the chamber holding the aerosol generating material and the aerosol generating material in the apparatus described above with reference to FIGS. 2 and 3 , and in the alternative embodiments discussed.
Consumable
According to a third aspect of the invention a consumable for a non-combustible aerosol provision system is provided comprising the aerosol generating material including combining a cut plant material and a cut tobacco material.
A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor. The consumable may also contain other non-tobacco products, which, depending on the product, may either contain nicotine or not contain it. It also may contain one or more humectants, such as glycerin or propylene glycol.
In some embodiments, the consumable is a cartridge or pod containing the aerosol generating material. In other embodiments, the consumable may be in the form of a rod or stick containing the aerosol generating material. For example, the rod or stick may be circumscribed with a wrapper. The rod or stick may comprise one or more additional sections, in addition to one or more sections comprising aerosol generating material. Such sections may include filtering sections, cooling sections, or sections with other materials that generate aerosol or modify the aerosol, for example by adding flavor.
Method for Preparing the Aerosol-Generating Material
According to a fourth aspect of the invention, a method of preparing the aerosol-generating material described herein is provided.
In a generalised example, preparing the aerosol generating material may involve the following steps.
The cut tobacco material may be prepared using a method including one or more the following steps: selecting the tobacco material; conditioning and casing; bulking, cutting; drying; and flavoring.
The cut plant material may be prepared by a method including one or more of the following steps: selecting the plant material; conditioning; bulking, cutting; and drying.
The cut tobacco material and cut plant material are then combined to form the aerosol generating material. The combination may be mixed or blended. Optionally, the aerosol generating material is incorporated into a consumable or into a non-combustible aerosol provision system.
The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future. The delivery system described herein can be implemented as a non-combustible aerosol provision system.

Claims

1. An aerosol generating material comprising cut tobacco material and cut plant material, the cut plant material having an average particle size of at least about 0.25 mm.

2. An aerosol generating material as claimed in claim 1, wherein the cut plant material has an average particle size of from about 0.3 mm to about 0.5 mm.

3. An aerosol generating material as claimed in claim 1, wherein the cut plant material comprises clove.

4. An aerosol generating material as claimed in claim 1, wherein the cut tobacco material comprises reconstituted tobacco.

5. An aerosol generating material as claimed in claim 1, comprising from about 25% to about 40% by weight of cut plant material based upon the weight of the aerosol generating material.

6. An aerosol generating material as claimed in claim 1, wherein the density of the aerosol generating material is from about 0.25 to about 0.45 g/cm³, and optionally from about 0.3 to about 0.4 g/cm³.

7. An aerosol generating material as claimed in claim 1, wherein the cut tobacco material has a cut size of from 20 to 25 CPI (cuts per inch), or from about 7.9 to about 9.8 cuts per cm.

8. An aerosol generating material as claimed in claim 1, having a water content of from about 8 to about 9%.

9. An aerosol generating material as claimed in claim 1, wherein the cut plant material is not immobilised within the aerosol generating material.

10. An aerosol generating material as claimed in claim 9, wherein the cut plant material is not incorporated into tobacco material.

11. An aerosol generating material as claimed claim 9, wherein the aerosol generating material does not include a binder to bond the cut tobacco material and cut plant material.

12. A non-combustible aerosol provision system comprising the aerosol generating material of claim 1.

13. A system as claimed in claim 12, wherein the system is an aerosol generating material heating system comprising an aerosol generating material which is to be heated to volatilise constituents, and optionally including a filter or filter element.

14. A system as claimed in claim 12, wherein the system is a hybrid system comprising an aerosol generating material which is to be heated to volatilise constituents, and a liquid which is to be heated to form a vapour, and optionally including a filter or filter element.

15. A system as claimed in claim 14, wherein the aerosol generating material is heated by the vapour.

16. A system as claimed in claim 15, wherein the liquid is a nicotine-free liquid.

17. A system as claimed in claim 15, wherein the system includes a means for heating the liquid to form a vapour, but does not include a separate means for heating the aerosol generating material.

18. A consumable comprising the aerosol generating material of claim 1.

19. A consumable as claimed in claim 18, comprising a cartridge or pod comprising the aerosol generating material.

20. A consumable as claimed in claim 18, comprising a rod or stick comprising the aerosol generating material.

21. A method of preparing the aerosol generating material of claim 1, comprising combining cut tobacco material and cut plant material.

22. A method as claimed in claim 21, wherein the cut tobacco material and cut plant material are combined by simple blending.