US20250212936A1 - A moisture-impermeable container containing an aerosol-generating material and uses thereof - Google Patents

A moisture-impermeable container containing an aerosol-generating material and uses thereof Download PDF

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Publication number
US20250212936A1
US20250212936A1 US18/851,527 US202318851527A US2025212936A1 US 20250212936 A1 US20250212936 A1 US 20250212936A1 US 202318851527 A US202318851527 A US 202318851527A US 2025212936 A1 US2025212936 A1 US 2025212936A1
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United States
Prior art keywords
aerosol
container
generating material
generating
moisture
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Pending
Application number
US18/851,527
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English (en)
Inventor
Stuart Martin
Robert Press
Sylwia Kuzmicka
Matthew Hodgson
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Nicoventures Trading Ltd
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Nicoventures Trading Limited
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Publication of US20250212936A1 publication Critical patent/US20250212936A1/en
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    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/18—Treatment of tobacco products or tobacco substitutes
    • A24B15/186—Treatment of tobacco products or tobacco substitutes by coating with a coating composition, encapsulation of tobacco particles
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/10—Chemical features of tobacco products or tobacco substitutes
    • A24B15/16—Chemical features of tobacco products or tobacco substitutes of tobacco substitutes
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/10—Chemical features of tobacco products or tobacco substitutes
    • A24B15/16—Chemical features of tobacco products or tobacco substitutes of tobacco substitutes
    • A24B15/167—Chemical features of tobacco products or tobacco substitutes of tobacco substitutes in liquid or vaporisable form, e.g. liquid compositions for electronic cigarettes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B63/00—Auxiliary devices, not otherwise provided for, for operating on articles or materials to be packaged
    • B65B63/08—Auxiliary devices, not otherwise provided for, for operating on articles or materials to be packaged for heating or cooling articles or materials to facilitate packaging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B9/00—Enclosing successive articles, or quantities of material, e.g. liquids or semiliquids, in flat, folded, or tubular webs of flexible sheet material; Subdividing filled flexible tubes to form packages
    • B65B9/06—Enclosing successive articles, or quantities of material, in a longitudinally-folded web, or in a web folded into a tube about the articles or quantities of material placed upon it
    • B65B9/08—Enclosing successive articles, or quantities of material, in a longitudinally-folded web, or in a web folded into a tube about the articles or quantities of material placed upon it in a web folded and sealed transversely to form pockets which are subsequently filled and then closed by sealing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D75/00—Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes or webs of flexible sheet material, e.g. in folded wrappers
    • B65D75/04—Articles or materials wholly enclosed in single sheets or wrapper blanks
    • B65D75/06—Articles or materials wholly enclosed in single sheets or wrapper blanks in sheets or blanks initially folded to form tubes
    • B65D75/12—Articles or materials wholly enclosed in single sheets or wrapper blanks in sheets or blanks initially folded to form tubes with the ends of the tube closed by flattening and heat-sealing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D75/00—Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes or webs of flexible sheet material, e.g. in folded wrappers
    • B65D75/28—Articles or materials wholly enclosed in composite wrappers, i.e. wrappers formed by associating or interconnecting two or more sheets or blanks
    • B65D75/30—Articles or materials enclosed between two opposed sheets or blanks having their margins united, e.g. by pressure-sensitive adhesive, crimping, heat-sealing, or welding
    • B65D75/32—Articles or materials enclosed between two opposed sheets or blanks having their margins united, e.g. by pressure-sensitive adhesive, crimping, heat-sealing, or welding one or both sheets or blanks being recessed to accommodate contents
    • B65D75/36—Articles or materials enclosed between two opposed sheets or blanks having their margins united, e.g. by pressure-sensitive adhesive, crimping, heat-sealing, or welding one or both sheets or blanks being recessed to accommodate contents one sheet or blank being recessed and the other formed of relatively stiff flat sheet material, e.g. blister packages, the recess or recesses being preformed
    • B65D75/367—Articles or materials enclosed between two opposed sheets or blanks having their margins united, e.g. by pressure-sensitive adhesive, crimping, heat-sealing, or welding one or both sheets or blanks being recessed to accommodate contents one sheet or blank being recessed and the other formed of relatively stiff flat sheet material, e.g. blister packages, the recess or recesses being preformed and forming several compartments

Definitions

  • the invention relates to a moisture-impermeable container containing an aerosol-generating material, methods of manufacturing the product and uses thereof.
  • 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 flavours. Factors such as the concentration of volatile active and/or flavour components in the aerosol generating materials and the stability of the aerosol-generating materials will influence the properties of the aerosol generated.
  • a moisture impermeable container comprising an aerosol-generating material comprising a dried precursor material comprising an extract from a flavour- and/or active-containing plant material.
  • the moisture impermeable container is to be opened or removed prior to use of the aerosol-generating material to provide access to the aerosol-generating material.
  • the container is selected from the group consisting of a wrapper, pouch, cartridge, capsule and blister.
  • the container is configured to be punctured, split or ruptured to provide access to the aerosol-generating material.
  • the container comprises a moisture impermeable sheet material.
  • the container comprises a rupturable capsule that is configured to rupture upon being compressed or crushed.
  • the container comprises a moisture-impermeable material that decomposes upon heating to provide access to the aerosol-generating material.
  • the container comprises one or more moisture-impermeable material selected from the group consisting of: a polysaccharide or cellulosic material, or a derivative thereof; a gum; a protein material; a polyol matrix material; a wax; a wax ester; and a polymer
  • the container comprises a single chamber containing the aerosol-generating material.
  • the container comprises multiple chambers containing the aerosol-generating material.
  • the or each chamber contains a portion of aerosol-generating material to provide a single puff of aerosol upon heating.
  • the or each chamber contains a portion of aerosol-generating material to provide multiple puffs of aerosol upon heating, optionally wherein the aerosol-generating material provides 6 to 9 puffs of aerosol when heated.
  • the aerosol-generating material has a water content of no more than about 5% (calculated on a wet weight basis).
  • the aerosol-generating material comprises an aerosol-former material.
  • the plant material is selected from the group consisting of tobacco, eucalyptus , star anise, cocoa and hemp.
  • the extract from a flavour- or active-containing plant material is an aqueous extract.
  • the aerosol-generating material comprises from about 40 to about 99% by weight tobacco solids.
  • a non-combustible aerosol-provision system comprising a container according to the first aspect and a non-combustible aerosol provision device.
  • the system is configured to open the container as it is inserted into the non-combustible aerosol provision device.
  • the non-combustible aerosol provision device includes a means for opening the container by puncturing, splitting or rupturing the container.
  • the means for opening the container is actuated by the action of inserting the container into the device.
  • the system is configured to heat the aerosol-generating material to form a vapour and/or aerosol.
  • the system comprises a further aerosol-generating material which is to be heated to form an aerosol and/or vapour, optionally wherein the further aerosol-generating material is a liquid.
  • the dried aerosol-generating material is heated by the aerosol and/or vapour generated from the further aerosol-generating material.
  • the system includes a means for heating the further aerosol-generating material to form a vapour, but not including a separate means for heating the dried aerosol-generating material.
  • a moisture-impermeable container according to the first aspect comprising:
  • the precursor material is dried by spray-drying or freeze-drying.
  • a moisture-impermeable container according to the first aspect comprising:
  • the precursor composition and/or the aerosol-generating material comprises an aerosol-former material.
  • the method comprises coating the outer surface of the container with a moisture impermeable coating.
  • FIG. 1 is schematic representation of a moisture impermeable pouch holding aerosol-generating material.
  • FIG. 2 is a cross-sectional view of a strip of moisture impermeable blisters holding aerosol-generating material.
  • FIG. 3 is a side-on cross-sectional view of a first embodiment of a consumable comprising a container as described herein;
  • FIG. 4 is a perspective illustration of a non-combustible aerosol provision device for generating aerosol from a consumable as shown in FIG. 3 .
  • An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way.
  • Conventional aerosol-generating materials which comprise tobacco material or a tobacco extract may be used in combustible and non-combustible aerosol-generating devices, including hybrid devices and tobacco heating products, to provide the user with an aerosol with an authentic tobacco taste and texture.
  • One issue encountered with such materials is that the content of the flavour, other volatile compound(s) and nicotine decreases with storage of the aerosol-generating material, dropping off particularly towards the end of the life of the material. This is because the more volatile components, including nicotine and many flavours and aromas, are readily released from the material.
  • the moisture content of the aerosol-generating material increases through moisture absorption, the release of substances such as nicotine and flavours is negatively impacted. Aerosol-generating materials that are produced using conventional methods and procedures commonly need to be used within one to three days of production. There is therefore a need to improve the shelf life of the aerosol generating material.
  • a further issue associated with conventional aerosol-generating materials comprising tobacco material or a tobacco extract is that the concentration of the desired components such as nicotine and flavours is relatively low. This limits the concentration of these desired components in the aerosol generated. Additionally, this means that a relatively large amount of the aerosol-generating material is needed and, accordingly, high amounts of energy are required to heat the aerosol-generating material in order to release the desired components.
  • the present invention relates to moisture-impermeable containers comprising a dried or dehydrated aerosol generating material formed from an extract from a flavour- and/or active-containing plant material.
  • this wrapper Whilst it is known for some consumables to include a wrapper surrounding the aerosol-generating material, this wrapper is usually paper and does not provide a moisture impermeable container that protects the aerosol-generating material from the moisture in the surrounding environment.
  • the extract is a liquid solution or suspension and it may be dried or dehydrated using a process such as spray-drying or freeze-drying.
  • the dried or dehydrated aerosol generating material may be formed from a precursor material comprising the extract from a flavour- and/or active-containing plant material and an aerosol-former material.
  • the aerosol-generating material comprising the dried extract from a flavour- and/or active-containing plant material comprises a high concentration of the flavour and/or active, with little or no material that does not contribute to the aerosol generated from the dried aerosol-generating material. As such, small amounts of the aerosol-generating material are sufficient to generate aerosol with desired active and flavour content. Further, the aerosol may be generated with the input of relatively low levels of energy.
  • aerosol-generating material being used as a solid substrate is that the low water content reduces issues associated with “hot puff”, which are known in the art.
  • the dried aerosol-generating material in the moisture impermeable pack has a moisture content of from o to about 10%, or from o to about 5% (calculated on a wet weight basis), as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer titration.
  • the moisture content of the dried aerosol-generating material is less than about 3 wt %, for example from about o to about 3 wt %, or from about 0.5 to about 2.5 wt %.
  • Karl Fischer titration is a classic method of chemical analysis for reliably determining the amount of water in a sample, and even just trace amounts. The method can be readily carried out using an automated Karl Fischer titrator. Similarly, the use of GC-TCD is also a well-established method for reliably determining the water content in a sample.
  • references to moisture content herein are references to the moisture content as measured by Karl Fischer titration.
  • a moisture-impermeable container containing the aerosol-generating material.
  • the container prevents exposure of the aerosol-generating material to moisture, thus preventing the absorption of moisture by the aerosol-generating material prior to its use.
  • the container may also be hermetically sealed.
  • the aerosol-generating material will be sealed in the moisture-impermeable container promptly after its manufacture or preparation. Where there is a delay in packaging the aerosol-generating material, the material should be kept in a controlled low-humidity environment.
  • the step of packaging a portion of the aerosol-generating material in a moisture-impermeable container is carried out in a controlled low-humidity environment to minimise the moisture absorbed by the aerosol-generating material before it is sealed in the container.
  • moisture impermeable containers comprising an aerosol-generating material comprising a dried precursor material comprising an extract from a flavour- and/or active-containing plant material and optionally an aerosol-former material, and a moisture impermeable housing surrounding the aerosol-generating material.
  • the hygroscopic aerosol-generating material in the moisture impermeable container has a moisture content of no greater than about 10% or no greater than about 5% (calculated on a wet weight basis), as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer titration.
  • GC-TCD gas chromatography-thermal conductivity detector
  • Karl Fischer titration This moisture content is stable, meaning that the moisture content of the aerosol-generating material is within this range not only when it is first prepared, but also after incorporation into the container and following transport and storage. This stable moisture content is observed despite the fact that the hygroscopic aerosol-generating material would rapidly absorb moisture if exposed to the environment, even under “normal” humidity conditions.
  • the aerosol-generating material when described as hygroscopic, this means that it will rapidly absorb water from the surrounding environment to significantly increase its water content. For example, upon exposure of the aerosol-generating material to the environment (for example, upon storage in an open container or the like), the moisture content rapidly increases to above 20% or above 25% (calculated on a wet weight basis), as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer titration.
  • GC-TCD gas chromatography-thermal conductivity detector
  • Karl Fischer titration Karl Fischer titration.
  • the moisture-impermeable containers disclosed herein form a moisture impermeable barrier around the aerosol-generating material formed by drying an extract from a flavour- and/or active-containing plant material. This is important as the dried aerosol-generating material has a strong tendency to absorb moisture from its environment, leading to the negative effects discussed above.
  • the moisture impermeable container is opened or removed prior to use of the aerosol-generating material. This allows access to the aerosol-generating material and enables components released from this material during use to exit the container. For example, in embodiments where the aerosol-generating material is heated to form an aerosol, the container needs to be opened or removed to allow the aerosol to leave the container.
  • the moisture impermeable container is selected from the group consisting of a wrapper, pouch, cartridge, pod, capsule and blister.
  • the container will contain a single consumable and the container will be opened or removed before or during use.
  • the container contains multiple consumables or portions of the aerosol-generating material.
  • the container may be configured to be resealable, so that those consumables or portions remaining in the container can continue to be protected from moisture after the container has been opened to remove a consumable or portion.
  • a wrapper or pouch may be flexible, for example formed from one or more moisture impermeable sheets.
  • the sheets may be bonded to one another to seal the wrapper or pouch once the portion of aerosol-generating material has been added.
  • the wrapper or pouch forms a chamber within which the aerosol-generating material is sealed.
  • the moisture impermeable sheets are formed from or consist of a moisture impermeable material.
  • the moisture impermeable sheet may comprise or consist of a metal sheet such as an aluminium foil or a high moisture barrier plastic (e.g. ACLAR® (fluoropolymer films that are moisture and nicotine resistant).
  • the sheet material comprises a moisture-permeable or porous material that is covered or coated with a layer of moisture impermeable material.
  • Such sheets may comprise laminates of materials, such as paper/pulp laminated with moisture resistant material (e.g. varnish).
  • the flexible sheet does not comprise polypropylene or polystyrene.
  • the pouch may be provided as a single pouch or as a series of connected pouches, each pouch holding aerosol-generating material to provide a single puff of aerosol or a series of puffs.
  • the plurality of pouches may all hold the same aerosol-generating material or two or more different aerosol-generating materials.
  • the series of connected pouches may be configured to allow a single pouch to be separated from the rest and inserted into an aerosol provision device. Alternatively, the series of connected pouches may be received in the device and sequentially opened and used.
  • FIG. 1 One example of a moisture impermeable pouch is shown in FIG. 1 .
  • the pouch 1 comprises two sheets 2 of porous material coated to render the sheets moisture impermeable. These sheets are fused or adhered along their edges to form a chamber within which an aerosol-generating material 3 is sealed.
  • the container is a cartridge or blister.
  • the cartridge or blister may comprise a rigid or semi-rigid body, defining an open chamber within which the aerosol-generating material is held.
  • the rigid or semi-rigid body is moulded.
  • the body may be formed from moisture-impermeable material, such as a suitable polymeric, plastic or metal material.
  • the body may be formed from moisture-permeable material that is rendered moisture impermeable thanks to a moisture-impermeable cover or coating.
  • the body may comprise moulded paper/pulp, for an environmentally friendly cartridge or blister.
  • the cartridge may be moved between an open and a closed and sealed configuration, to allow the aerosol-generating material to be added and then sealed inside the cartridge. Upon use, the cartridge is opened again to allow access to the aerosol-generating material and to allow the aerosol generated upon use to be released.
  • the cartridge or blister includes an opening that may be temporarily sealed, for example by a stopper or cover.
  • suitable covers to seal the opening may comprise a sheet material, such as a moisture impermeable sheet material as discussed above. This sheet material may be attached to the edge of the opening, for example using an adhesive or by welding.
  • the blister may be provided as a single blister or as a plurality of connected blisters, each blister holding aerosol-generating material to provide a single puff of aerosol or a series of puffs.
  • the plurality of blisters may all hold the same aerosol-generating material or two or more different aerosol-generating materials.
  • the plurality of blisters may be configured to allow a single blister to be separated from the rest and inserted into an aerosol provision device. Alternatively, the plurality of connected blisters may be received in the device and sequentially opened and used.
  • the plurality of blisters may be formed from a single rigid or semi-rigid body shaped to provide a plurality of open chambers, each to hold a portion of aerosol-generating material.
  • the openings of the chambers may be sealed with a single moisture impermeable sheet.
  • the chambers may be arranged in a linear arrangement, or in a circle, or in any other configuration.
  • the blister strip 11 comprises a series of connected blisters.
  • the blister strip is formed from a shaped body portion 12 forming a series of open chambers within which the aerosol-generating material may be placed before the chambers are sealed by a moisture impermeable sheet 13 , such as a metal foil.
  • the moisture impermeable sheet 13 is welded to the shaped body portion 12 to form a series of sealed chambers holding the aerosol-generating material.
  • the blisters may be opened by penetrating or slitting the moisture impermeable sheet 13 with a blade or the like.
  • the container is a capsule.
  • a capsule may take the form of a rigid or semi-rigid shell, defining a chamber within which the aerosol-generating material is held.
  • the capsule shell material may, in some cases, be moisture impermeable. In other embodiments, the shell may be coated with a moisture-impermeable coating. In some embodiments, the capsule can be ruptured (i.e. crushed) to open the container and provide access to the contents, and to allow the aerosol generated from the aerosol-generating material to be released. In such embodiments, the capsule shell material is frangible or breakable. For example, the capsule may be crushed or otherwise fractured or broken by the user to open the container and provided access to its contents.
  • the crushing of the capsule may, for example, take place before the capsule is inserted into an aerosol-generating device.
  • the shell can be ruptured under the pressure imposed by the user's fingers (or any other pressure creating means) when the user is ready to use the aerosol-generating contents of the capsule.
  • the capsule is crushed by the user during use, to give a flavour boost at a point during use of the aerosol-provision system.
  • the capsule may have a crush strength from about 0.8 kp to about 3.5 kp, suitably from about 1.0 kp to about 2.5 kp or from about 1.0 to about 2.0 kp.
  • the capsules described herein may be substantially spherical and have a diameter of at least about 0.4 mm, 0.6 mm, 0.8 mm, 1.0 mm, 2.0 mm, 2.5 mm, 2.8 mm or 3.0 mm.
  • the diameter of the capsules may be less than about 10.0 mm, 8.0 mm, 7.0 mm, 6.0 mm, 5.5 mm, 5.0 mm, 4.5 mm, 4.0 mm, 3.5 mm or 3.2 mm.
  • the capsule diameter may be in the range of about 0.4 mm to about 10.0 mm, about 0.8 mm to about 6.0 mm, about 2.5 mm to about 5.5 mm or about 2.8 mm to about 3.2 mm.
  • the capsule may have a diameter of about 3.0 mm to about 3.5 mm.
  • the shell comprises from about 5 to about 90% by weight based on the total capsule shell weight of a gelling agent. In some cases, the shell comprises from about 5 to about 60%, from about 5 to about 50% or from about 10 to about 35% by weight based on the total capsule shell weight of the said gelling agent.
  • Suitable gelling agents which may be included in the capsule shell material may include, without limitation, polysaccharide or cellulosic gelling agents, gelatins, gums, gels, waxes or a mixture thereof.
  • Suitable polysaccharides include alginates, dextrans, maltodextrins, cyclodextrins, carrageenans and pectins.
  • Suitable alginates include, for instance, a salt of alginic acid, an esterified alginate or glyceryl alginate.
  • the barrier material comprises sodium alginate and/or calcium alginate.
  • Suitable cellulosic materials include methyl cellulose, ethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, cellulose acetate and cellulose ethers.
  • the gelling agent may comprise one or more modified starches.
  • the gelling agent may comprise one or more carrageenans.
  • Suitable gums include agar, gellan gum, gum arabic, pullulan gum, mannan gum, gum ghatti, gum tragacanth, Karaya, locust bean, acacia gum, guar, quince seed and xanthan gums.
  • Suitable gels include agar, agarose, carrageenans, furoidan and furcellaran.
  • Suitable waxes include carnauba wax.
  • the gelling agent may comprise carrageenans and/or gellan gum; these gelling agents are particularly suitable for inclusion as the gelling agent as the pressure required to break the resulting capsules is particularly suitable.
  • the capsule shell does not comprise gelatin.
  • the capsule shell may additionally comprise one or more of a bulking agent, a buffer, a colouring agent, and a plasticiser.
  • the plasticiser may be selected from the group consisting of: glycerol, sorbitol, maltitol, triacetin, polyethylene glycol, propylene glycol or another polyalcohol with plasticising properties, and optionally one acid of the monoacid, diacid or triacid type, especially citric acid, fumaric acid, malic acid, and the like.
  • the amount of plasticiser ranges from about 1% to about 30% by weight, from about 2% to about 15% by weight, or from about 3 to about 10% by weight of the total weight of the shell.
  • the total amount in the shell of plasticiser and gelling agent combined is about 40-70%, suitably about 50-60% by weight based on the total capsule shell weight.
  • the plasticiser comprises, consists essentially of or consists of glycerol.
  • the capsule shell may comprise a hydrophobic outer layer which increases the moisture-resistance of the container.
  • the hydrophobic outer layer is suitably selected from the group comprising waxes, especially carnauba wax, candelilla wax or beeswax, carbowax, shellac (in alcoholic or aqueous solution), ethyl cellulose, hydroxypropyl methyl cellulose, hydroxyl-propylcellulose, latex composition, polyvinyl alcohol, or a combination thereof.
  • the at least one moisture barrier agent is ethyl cellulose or a mixture of ethyl cellulose and shellac.
  • the containers described herein may be opened before the aerosol-generating material held therein is to be used.
  • the user may open the container manually, optionally removing the aerosol-generating material.
  • the container may be opened as it is inserted into an aerosol-generating device.
  • the device may include a means for puncturing or splitting the pouch and this acts as a result of the action of inserting the container into the device.
  • the opening means may be actuated separately, for example, by the user, when the device is to be used to generate an aerosol.
  • the container may open upon exposure to heat.
  • the container or part thereof may decompose upon heating to provide access to the aerosol-generating material.
  • an opening in the container body may be closed with a stopper or sheet comprising a material that decomposes when heated.
  • the container may comprise a porous material that is surrounded by or coated with a moisture impermeable layer that decomposes at a temperature to which the container and aerosol-generating material are exposed during use. As the temperature-sensitive moisture-impermeable material decomposes, the container becomes permeable, allowing the aerosol generated by the aerosol-generating material to be released from the container.
  • the decomposition of the coating or material on heating involves it losing its physical integrity so that it no longer forms a moisture-impermeable barrier. This may, for example, involve the material melting, crumbling, disintegrating or otherwise breaking down.
  • the materials should therefore be selected so that the moisture impermeable container remains intact when exposed to normal environmental temperatures. Therefore, in some embodiments, the materials used should be ones that form moisture impermeable coatings or parts that are stable at temperatures below 40 or 50° C. In some embodiments, it may be desirable to select a material that will form a moisture impermeable coating or part that remains intact during more extreme temperatures that may be encountered during storage and transport, such as those of 60 to 80° C.
  • the container comprises a heat-sensitive moisture impermeable material that becomes permeable when the temperature is raised to about 100 to 110° C., so as to avoid superheating any moisture present in the aerosol-generating material held within the container.
  • the container opens rapidly upon heating to form an aerosol. This will reduce the likelihood of the container interfering with the volatilisation and the release of the resultant gas or vapour.
  • the temperature at which the heat-sensitive moisture impermeable material becomes permeable is at least about 50° C., at least about 60° C., at least about 70° C. at least about 80° C., at least about 90° C., at least about 100° C., at least about 110° C., at least about 120° C. at least about 130° C., at least about 140° C., at least about 150° C., at least about 160° C., at least about 170° C., at least about 180° C., at least about 190° C. or at least about 200° C.
  • the temperature at which the heat-sensitive moisture impermeable material becomes permeable is no more than about 280° C., no more than about 270° C., no more than about 260° C., no more than about 250° C., no more than about 240° C., no more than about 230° C., no more than about 220° C., no more than about 210° C.
  • the heat-sensitive moisture impermeable coating or material comprises one or more material selected from: a polysaccharide or cellulosic material, or a derivative thereof; a gum; a protein material; a polyol matrix material; a wax; a wax ester; and a polymer.
  • Suitable polysaccharides include, for example, agar, agarose, pectin, furoidan, furcellan, alginates, carrageenans, starches, dextrans, maltodextrins and cyclodextrins.
  • Suitable cellulosic materials include, for example, methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, hydroxypropyl methylcellulose (HPMC), hydroxyethyl cellulose (HEC), cellulose acetate butyrate (CAB); cellulose acetate phthalate (CAP), cellulose acetate trimellitate (CAT) and cellulose acetate succinate (CAS), and cellulose ethers.
  • Suitable modified starches include, for example, high-amylose starches, hydroxypropylated starches, octenyl succinate modified starches, starch esters, and starch-based polyelectrolyte complexes (SPECs).
  • Suitable gums include, for example, gum arabic (acacia gum), guar gum, gum karaya, gum tragacanth, gum ghatti, quince seed gum, locust bean gum and xanthan gum.
  • Suitable proteins include zein and gelatin.
  • Suitable polyol matrixes may be formed from polyvinyl alcohol.
  • Suitable waxes include, for example, palmitic acid, carnauba wax, beeswax, candelilla wax, and paraffin wax.
  • Suitable wax esters include, for example, cetyl palmitate and triacontanyl palmitate.
  • Suitable polymers include, for example, shellac, lignin, polyvinyl alcohol, polyurethane, polymerised, hydrolysed ethylene vinyl acetate, a polyester, a polycarbonate, a polymethacrylate, a polyglycol, polyethylene, polystryrene, polypropylene, and polyvinyl chloride.
  • Suitable co-polymers include, for example, methacrylic acid copolymers, and acrylic acid copolymers.
  • the coating will be thick enough to confer the desired moisture impermeability.
  • the thickness of the coating may, in some embodiments, further influence the temperature at which the coating becomes permeable and allows volatile components generated by heating the aerosol-generating material to be released from the container.
  • the thickness of the coating may also, in some embodiments, influence the rate at which the coating becomes permeable once exposed to the temperature of decomposition. This may allow the rate of release of the volatile components from the heated aerosol-generating material to be controlled.
  • the containers will have suitable dimensions to accommodate this amount of aerosol-generating material, whilst also being of a size that is easy to manufacture and handle.
  • 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.
  • the tobacco material may be provided in the form of cut rag tobacco.
  • the cut rag tobacco can have a cut width of at least 15 cuts per inch (about 5.9 cuts per cm, equivalent to a cut width of about 1.7 mm) for example.
  • the cut rag tobacco can be formed from a mixture of forms of tobacco material, for instance a mixture of one or more of paper reconstituted tobacco, leaf tobacco, extruded tobacco and bandcast tobacco.
  • the precursor material comprises at least about 10 wt %, about 20 wt %, at least about 30 wt %, at least about 40 wt %, at least about 50 wt %, at least about 60 wt %, at least about 70 wt %, at least about 80 wt %, or at least about 90 wt % extract from a tobacco or other flavour- or active-substance containing plant material (calculated on a wet weight basis).
  • precursor material may comprise up to about 99 wt %, up to about 90 wt %, up to about 80 wt %, up to about 70 wt % or up to about 60 wt % extract from tobacco or other flavour- or active-substance containing plant material (calculated on a wet weight basis).
  • the precursor material comprises around 50 wt % tobacco extract (calculated on a wet weight basis).
  • the aerosol-generating material may comprise at least about 45 wt %, at least about 50 wt %, at least about 60 wt %, at least about 70 wt %, at least about 80 wt %, at least about 90 wt %, or at least about 95 wt % tobacco material or tobacco extract, or flavour- or active-substance containing plant material extract (calculated on a dry weight basis). In some embodiments, the aerosol-generating material may comprise about 60 to about 80 wt % tobacco extract (calculated on a dry weight basis).
  • the tobacco extract has a solids content of between about 40 and about 65 wt %, between about 45 and about 65 wt %, or between about 40 and about 60 wt % (calculated on a wet weight basis).
  • the water content of the tobacco extract is between about 35 wt % and about 65 wt %, or between about 35 and about 55 wt % (calculated on a wet weight basis).
  • the nicotine content of the tobacco extract is between about 1 wt % and about 5 wt % (calculated on a wet weight basis).
  • any particles in the precursor composition may be desirable for any particles in the precursor composition to have an average particle size of no greater than about 3 mm, of no greater than 1 mm, of no greater than about 0.5 mm, or to have an average particle size of no greater than about 0.3 mm, when measured by sieving or by observing the size of the particles by SEM.
  • the water content of the precursor material may be up to about 95 wt %, up to about 90 wt %, up to about 85 wt %, up to about 80 wt %, up to about 75 wt %, up to about 70 wt %, up to about 65 wt %, up to about 60 wt %, up to about 55 wt % or up to about 50 wt % on a wet weight basis.
  • the water content of the precursor material is between about 40 and about 50 wt % on a wet weight basis (50% and 60 v/v %). When the precursor material has a lower water content, the spray/freeze-drying process is quicker, as there is less water to remove.
  • the dried aerosol-generating material and/or the precursor material comprises one or more active substance. This may be derived from the extract or it may be added. In some embodiments, the extract from a flavour- or active-substance containing plant material comprises an active substance.
  • the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.
  • the precursor material may comprise an extract from other botanical source(s) along with or instead of the tobacco extract.
  • the extract may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof.
  • botanical includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like.
  • the extract may comprise or be derived from botanicals in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like.
  • Example 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
  • 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
  • the extract comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof selected from eucalyptus , star anise, cocoa and hemp.
  • the aerosol-generating material and/or the precursor material comprises one or more cannabinoid compounds selected from the group consisting of: cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM) and cannabielsoin (CBE), cannabicitran (CBT).
  • CBD cannabidiol
  • THC tetrahydrocannabinol
  • THCA tetrahydroc
  • the aerosol-generating material and/or the precursor material may comprise one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).
  • CBD cannabidiol
  • THC tetrahydrocannabinol
  • the aerosol-generating material and/or the precursor material may comprise cannabidiol (CBD).
  • CBD cannabidiol
  • the aerosol-generating material and/or the precursor material may comprise nicotine and cannabidiol (CBD).
  • CBD cannabidiol
  • the aerosol-generating material and/or the precursor material may comprise nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).
  • the aerosol-generating material further comprises an aerosol-former material.
  • this aerosol-former material is included in the precursor material.
  • the aerosol-former material may comprise one or more constituents capable of forming an aerosol.
  • the aerosol-former may be, for instance, a polyol aerosol generator or a non-polyol aerosol generator. It may be a solid or liquid at room temperature, but preferably is a liquid at room temperature.
  • 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 aerosol former comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and/or aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.
  • the aerosol-former material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, vegetable glycerine (VG), triacetin, sorbitol and xylitol.
  • the aerosol-former material comprises, consists essentially of or consists of glycerol.
  • Glycerol provides a visible aerosol when the aerosol-generation device is used. It is common that consumers like the aerosol generating device to provide a visible aerosol, as this enables the consumer to visualise the product and what they are consuming. This makes glycerol a desirable choice for aerosol former material.
  • Propylene glycol has the benefit that it is a better flavour carrier than glycerol.
  • a combination of two or more aerosol forming agents may be used, in equal or differing proportions.
  • the precursor material comprises at least about 1 wt %, at least about 5 wt %, at least about 10 wt %, or at least about 20 wt % aerosol-former material (calculated on a wet weight basis). Additionally or alternatively, the precursor material may comprise up to about 40 wt %, up to about 35, up to about 30 wt %, up to about 25 wt %, up to about 20 wt %, or up to about 10 wt % aerosol-former material (calculated on a wet weight basis).
  • the amount of glycerol in the precursor material, and therefore the dried aerosol material is important because it is both an aerosol-forming material and also a plasticizer. If the concentration of glycerol it too high, it may be detrimental to a critical temperature of the product during the freeze-drying process and may result in collapse of the product if the critical temperature of the formulation is exceeded. On the other hand, sufficient glycerol should be included to provide the consumer with an adequate and pleasing aerosol.
  • the freeze dried material used as the aerosol-generating material according to the present invention has a particle size distribution D10 from about 8 to about 15 ⁇ m, a particle size distribution D50 from about 50 to about 150 ⁇ m, and a particle size distribution D90 from about 900 to about 1700 ⁇ m.
  • the precursor material is sprayed and rapidly dried using a hot gas.
  • spray drying provides several advantages to the present invention: the dry particle size can be controlled and may be consistent; tobacco or flavour extracts or materials are heat sensitive but can still be spray-dried at relatively high inlet temperatures; a short residence time in the spray-drying equipment is required; and minimal loss of flavour/volatiles. This makes the process adaptable to reduce loss of volatile compounds and maintain the desired flavour of the aerosol generating material.
  • Freeze-drying also known as lyophilisation or cryodesiccation, is a process in which the precursor material is frozen, the temperature lowered and the water is removed via sublimation under reduced pressure conditions. Without wishing to be bound by any specific theory, it is believed that the low processing temperatures and rapid water loss via sublimation avoid changes in the aerosol-generating material's structure, appearance and characteristics. This process preserves the structure of the precursor material, and reduces the loss and decomposition of volatile flavour compounds.
  • the dried aerosol-generating material has a water content of less than about 5 wt %, less than about 4 wt %, less than about 3 wt %, less than about 2 wt % or less than about 1 wt % (calculated on a wet weight basis), as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer measurement.
  • GC-TCD gas chromatography-thermal conductivity detector
  • the precursor material comprises Burley tobacco extract and a water content of 60 wt %.
  • the dried aerosol generating material has a water content of 3 wt %.
  • a lower water content of the dried aerosol-generating material is associated with longer shelf-life and stability. However, very low water content may be associated be a brittle structure and a smaller particle size, as well as taking longer to process.
  • the material is also very hygroscopic. If the water content of the dried aerosol-generating material is too high on the other hand, the desired increased stability may not be achieved.
  • the dried aerosol-generating material may also not be as easy to handle with higher water content, with the material becoming sticky.
  • the precursor material comprises an excipient
  • the precursor material may be better suited to being dried via spray-drying (compared to a precursor material without an excipient).
  • increasing the amount of the excipient in the precursor material raises the glass transition temperature to above 100° C. and this affects the physical properties of the material, making it more suitable for spray drying.
  • the precursor material may be placed in the container and dried in situ, to form the aerosol-generating material in the container which is subsequently sealed.
  • the preferred drying process may be freeze-drying. This in situ drying of the precursor material may minimise the exposure of the aerosol-generating material to moisture before the container is opened just before or during use.
  • the containers comprising the aerosol-generating material may be used in combustible or non-combustible aerosol provision systems, or in an aerosol-free delivery system.
  • the container may hold, in addition to the aerosol-generating material, a further, different aerosol-generating material, such as tobacco material in the form of cut rag or reconstituted tobacco material.
  • 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 heater may, in some embodiments, be provided within the container with the aerosol-generating material. In some embodiments, the heater may form part of the housing of the container.
  • the container protects the moisture sensitive aerosol-generating material, it is not necessary for the container or the consumable to be stored in reduced humidity conditions prior to use.
  • the total mass of the dried aerosol generating material included for use in a delivery system is up to about 200 mg, up to about 190 mg, up to about 180 mg, up to about 170 mg, up to about 160 mg, up to about 150 mg, up to about 140 mg, up to about 130 mg, up to about 120 mg, up to about 110 mg, up to about 100 mg, up to about 90 mg, up to about 80 mg, up to about 70 mg, up to about 60 mg, or up to about 50 mg.
  • the total mass of the dried aerosol generating material included may be at least about 5 mg, at least about 10 mg, at least about 15 mg, at least about 20 mg, at least about 25 mg, at least about 30 mg, at least about 35 mg, at least about 40 mg, at least about 45 mg, or at least about 50 mg.
  • the delivery systems described herein can be combustible aerosol provision systems, non-combustible aerosol provision systems or an aerosol-free delivery systems.
  • the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.
  • a component for use in a combustible aerosol provision system such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.
  • 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.
  • the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.
  • 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.
  • END electronic nicotine delivery system
  • the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system.
  • a heat-not-burn system is a tobacco heating system.
  • 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.
  • the disclosure relates to consumables comprising a container comprising an aerosol-generating material and configured to be used with non-combustible aerosol provision devices.
  • consumables are sometimes referred to as articles throughout the disclosure.
  • the non-combustible aerosol provision system may comprise a power source and a controller.
  • the power source may, for example, be an electric power source or an exothermic power source.
  • the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to a composition comprising an aerosol-generating material and a moisture impermeable coating or to a heat transfer material in proximity to the exothermic power source.
  • 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.
  • the consumable for use with the non-combustible aerosol provision device may comprise a composition comprising an aerosol-generating material and a moisture impermeable coating, 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.
  • FIG. 4 shows an example of a non-combustible aerosol provision device 100 for generating aerosol from an aerosol-generating medium/material such as the composition of a consumable 110 , as described herein.
  • the device 100 may be used to heat a replaceable article 110 comprising the aerosol-generating medium, for instance an article as described elsewhere herein, to generate an aerosol or other inhalable medium which is inhaled by a user of the device 100 .
  • the device 100 and replaceable article 110 together form a system.
  • the device 100 comprises a housing 102 (in the form of an outer cover) which surrounds and houses various components of the device 100 .
  • the device 100 has an opening 104 in one end, through which the article 110 may be inserted for heating by a heating assembly.
  • the article 110 may be fully or partially inserted into the heating assembly where it may be heated by one or more components of the heater assembly.
  • the article 110 is illustrated having a rod-shape, like the consumable 20 illustrated in FIG. 3 .
  • the article have a different shape and may even be a container as shown in FIG. 1 or FIG. 2 , with a suitably adapted device and opening.
  • the device 100 of this example comprises a first end member 106 which comprises a lid 108 which is moveable relative to the first end member 106 to close the opening 104 when no article 110 is in place.
  • the lid 108 is shown in an open configuration, however the lid 108 may move into a closed configuration.
  • a user may cause the lid 108 to slide in the direction of arrow “B”.
  • the device 100 may also include a user-operable control element 112 , such as a button or switch, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the switch 112 . This switch may also actuate the means for opening the container inserted into the device, in readiness for its use.
  • a user-operable control element 112 such as a button or switch, which operates the device 100 when pressed.
  • a user may turn on the device 100 by operating the switch 112 .
  • This switch may also actuate the means for opening the container inserted into the device, in readiness for its use.
  • the device 100 may also comprise an electrical component, such as a socket/port 114 , which can receive a cable to charge a battery of the device 100 .
  • the socket 114 may be a charging port, such as a USB charging port.
  • the glycerol content of the precursor and dried aerosol-generating material after the freeze drying process has been calculated, providing an indication of the amount of glycerol retained following the processing.
  • the glycerol recovery of the dried aerosol generating material is at least about 85%.
  • the glycerol recovery of the dried aerosol generating material compared to the precursor material may be at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90% at least about 95% on a dry weight basis.
  • a tablet is formed by pressing 100 mg of the freeze-dried material of Example 1 or Example 2. Under nitrogen, this tablet is then placed inside an open pouch formed by folding an aluminium sheet and sealing along two edges. Then, the pouch is closed by sealing along the open edge.

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  • General Chemical & Material Sciences (AREA)
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  • Manufacture Of Tobacco Products (AREA)
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US18/851,527 2022-04-01 2023-03-31 A moisture-impermeable container containing an aerosol-generating material and uses thereof Pending US20250212936A1 (en)

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