WO2014083333A1 - Contrôle d'une matière à fumer - Google Patents

Contrôle d'une matière à fumer Download PDF

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Publication number
WO2014083333A1
WO2014083333A1 PCT/GB2013/053132 GB2013053132W WO2014083333A1 WO 2014083333 A1 WO2014083333 A1 WO 2014083333A1 GB 2013053132 W GB2013053132 W GB 2013053132W WO 2014083333 A1 WO2014083333 A1 WO 2014083333A1
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WO
WIPO (PCT)
Prior art keywords
smokeable material
smokeable
inorganic filler
binder
slurry
Prior art date
Application number
PCT/GB2013/053132
Other languages
English (en)
Inventor
Martin Coleman
Edward Dennis John
Samuel Paul WHIFFEN
Garrick Thorn
Original Assignee
British American Tobacco (Investments) Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by British American Tobacco (Investments) Limited filed Critical British American Tobacco (Investments) Limited
Publication of WO2014083333A1 publication Critical patent/WO2014083333A1/fr

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Classifications

    • 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
    • A24B15/12—Chemical features of tobacco products or tobacco substitutes of reconstituted tobacco
    • A24B15/14—Chemical features of tobacco products or tobacco substitutes of reconstituted tobacco made of tobacco and a binding agent not derived from tobacco
    • 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
    • A24B15/28—Treatment of tobacco products or tobacco substitutes by chemical substances
    • A24B15/42—Treatment of tobacco products or tobacco substitutes by chemical substances by organic and inorganic substances
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D1/00—Cigars; Cigarettes
    • A24D1/18—Selection of materials, other than tobacco, suitable for smoking

Definitions

  • the invention relates to smokeable materials, particularly, but not exclusively, to a method of controlling the filling value of a smokeable material.
  • Smoking articles may comprise tobacco substitute smokeable materials or alternative smokeable materials. Such smokeable materials may be configured to provide specific characteristics to the smoking article. For example, some smokeable materials may provide taste and/ or flavour characteristics, such as a taste and flavour resembling that provided by tobacco. Some smokeable materials may provide specific combustion characteristics, and may for example alter the burn rate of a product. Some smokeable materials may be designed to reduce the amount of tobacco required in the smoking material blend.
  • This disclosure provides a method of controlling the filling value of a smokeable material.
  • the method comprises controlling the relative levels of inclusion in the smokeable material of at least two inorganic filler materials having different bulk densities and/ or the foam structure of the aerated smokeable material.
  • a smokeable material having a desired filling value maybe obtained by adjusting certain aspects of the composition of the smokeable material during its production.
  • controlling the relative proportions of at least two inorganic filler materials having different bulk densities included in the smokeable material, and/ or the foam structure of the aerated smokeable material may allow the filling value of the smokeable material to be controlled as required.
  • Smokeable materials produced using the disclosed method may have a non- foamed structure or a foamed structure which has any degree of foam character ranging from a non-foamed material to a highly foamed material comprising a significantly aerated cellular structure.
  • the disclosed method also allows the production of smokeable materials comprising an amount of inorganic filler ranging from no inorganic filler material to a significant amount of inorganic filler material, which may comprise at least two inorganic filler materials having different bulk densities.
  • the filling value of the material may be predominantly controlled by controlling the relative levels of inclusion of at least two inorganic filler materials having different bulk densities. Conversely, in the case of smokeable materials which have a foamed structure, the filling value of the material may be predominantly controlled by controlling the foam structure of the smokeable material.
  • the method comprises producing an aerated smokeable material from a slurry comprising a binder, and controlling the foam structure comprises controlling the amount of binder present in the slurry.
  • the binder may comprise a combination of two or more binders, and in these embodiments, controlling the foam structure may in addition, or alternatively, comprise controlling the relative levels of inclusion in the slurry of the two or more binders.
  • the method comprises producing an aerated smokeable material from a slurry comprising a binder, and using a cross- linking agent to cross-link the binder. In these embodiments controlling the foam structure may comprise controlling the degree of cross-linking.
  • the binder may comprise a combination of two or more binders, and in this case, controlling the foam structure may further comprise controlling the relative levels of inclusion in the slurry of the two or more binders.
  • the method comprises producing an aerated smokeable material from a slurry comprising a binder, wherein the degree of aeration of the slurry is measured as overrun.
  • Producing a foam structure may involve controlling the overrun of the slurry.
  • the binder may comprise a combination of two or more binders, and in this case, controlling the foam structure may further comprise controlling the relative levels of inclusion in the slurry of the two or more binders.
  • the method comprises producing an aerated smokeable material from a slurry comprising a binder, and using a cross- linking agent to cross-link the binder.
  • controlling the foam structure may comprise controlling the amount of binder present in the slurry, and the degree of cross-linking.
  • the binder may comprise a combination of two or more binders, and in this case, controlling the foam structure may further comprise controlling the relative levels of inclusion in the slurry of the two or more binders.
  • the method comprises producing an aerated smokeable material from a slurry comprising a binder, wherein the degree of aeration of the slurry is measured as overrun.
  • controlling the foam structure may comprise controlling the amount of binder present in the slurry, and the overrun of the slurry.
  • the binder may comprise a combination of two or more binders, and in this case, controlling the foam structure may further comprise controlling the relative levels of inclusion in the slurry of the two or more binders.
  • the method comprises producing an aerated smokeable material from a slurry comprising a binder, and using a cross- linking agent to cross-link the binder, wherein the degree of aeration of the slurry is measured as overrun.
  • controlling the foam structure may comprise controlling the degree of cross-linking and the overrun of the slurry.
  • the binder may comprise a combination of two or more binders, and in this case, controlling the foam structure may further comprise controlling the relative levels of inclusion in the slurry of the two or more binders.
  • the method comprises producing an aerated smokeable material from a slurry comprising a binder, and using a cross- linking agent to cross-link the binder, wherein the degree of aeration of the slurry is measured as overrun.
  • controlling the foam structure may comprise controlling the amount of binder present in the slurry, controlling the degree of cross-linking, and the overrun of the slurry.
  • the binder may comprise a combination of two or more binders, and in this case, controlling the foam structure may further comprise controlling the relative levels of inclusion in the slurry of the two or more binders.
  • both the relative levels of inclusion of filler materials having different bulk densities, and the foam structure may be used to control the filling value, these two properties may be controlled in combination to control the filling value of the smokeable material.
  • the filling value of materials which have a substantially foamed structure and are substantially free of inorganic filler will be predominantly controlled by means of the foam structure.
  • the filling value of materials which are essentially non-foamed, and comprise a substantial proportion of inorganic filler material will be predominantly controlled by means of the relative levels of inclusion of the inorganic filler materials with different bulk densities.
  • a method of controlling the filling value of a foamed smokeable material comprising the following steps:
  • Both the relative levels of inclusion of the first and second inorganic filler materials, and also the foam structure are controlled to produce a smokeable material having a controlled filling value.
  • the foam structure may be controlled by controlling the amount and composition of the binder in the slurry, the degree of aeration of the slurry, and the extent to which the binder is cross-linked.
  • Smokeable materials produced using this method may therefore have a relatively non-foamed structure or a foamed structure which has any degree of foam character ranging from a relatively non-foamed material to a highly foamed material comprising a significantly aerated cellular structure.
  • the filling value of the smokeable material may be controlled to be in the rang of about o.5cm3/g to about 20cm3/g, preferably about lcms/g to about I2cm3/g, and maybe in the range of between about 2cms/g to about locms/g.
  • a method of controlling the filling value of a smokeable material wherein the smokeable material has a non-foamed structure comprising the following steps: (i) preparing a slurry comprising binder, an aerosol generating means, a first particulate inorganic filler material having a lower bulk density, and a second particulate inorganic filler material having a higher bulk density; and,
  • the relative levels of inclusion of the first and second inorganic filler materials may be controlled to provide the smokeable material having a controlled filling value.
  • the filling value of the smokeable material produced by the disclosed method, having a non-foamed structure may be controlled to be in the range of about o.5cm 3 /g to about 7cm3/g, and may be in the range of between about i.5cm3/g to about 6cm3/g, such as less than about 4.3cm3/ g.
  • the total amount of inorganic filler material present in the non-foamed smokeable material may be in the range of from about io% to about 90%, such as from about 20% to about 85% by weight of the smokeable material.
  • the first particulate inorganic filler material may have a bulk density in the range of from about o.oig/ cm 3 to about o.3g/cm 3 and may be expanded perlite or expanded vermiculite.
  • the second particulate inorganic filler material may have a bulk density in the range of from about o.6g/cm 3 to about 6g/cm 3 and may be calcium carbonate.
  • the bulk densities of one or both of the inorganic filler materials may be outside of these ranges, provided that the bulk densities of the two inorganic filler materials are different.
  • the inorganic filler materials may be different materials, or may be different types of the same material, the different types of the same material having different bulk densities.
  • the two inorganic filler materials may be included in the smokeable material in any relative proportion. For example, in some smokeable materials, the two inorganic filler materials may be included in approximately similar amounts. In contrast, in other smokeable materials, one of the inorganic filler materials may be included in only very small amount, with the filler content of the smokeable material almost entirely comprising only the other filler material.
  • smokeable materials may comprise any relative proportion of inorganic filler materials between these two extreme examples.
  • the relative levels of inclusion in the smokeable material of the two inorganic filler materials is in the range of 1:100 to 100: 1 by weight.
  • a method of controlling the filling value of a smokeable material wherein the smokeable material has a foamed or substantially foamed structure comprising the following steps: (i) preparing a slurry comprising binder, an aerosol generating means, and a foaming agent, wherein the binder and the foaming agent may or may not be the same agent;
  • the filling value of the smokeable material produced by the disclosed method, having a foamed or substantially foamed structure may be controlled to be in the range of about 3cm3/g to about I2cm3/g, and maybe in the range of between about 5cm3/g to about iocm3/g, such as more than about 5.6cm3/g.
  • the foaming agent may be hydroxypropyl cellulose, methyl cellulose, ethyl cellulose, starch, modified starch, protein, or a sugar ester, and may be present in the range of from about 0.5% to about 70%, such as from about 3% to about 30% by weight of the dry smokeable material.
  • the foaming agent may be a foamable binder, which may be an esterified alginate such as propylene glycol alginate, and may be present in the range of from about 5% to about 90%, such as from about 10% to about 80% by weight of the dry smokeable material.
  • a foamable binder which may be an esterified alginate such as propylene glycol alginate, and may be present in the range of from about 5% to about 90%, such as from about 10% to about 80% by weight of the dry smokeable material.
  • the binder may be a combination of foamable and non-foamable binders and controlling the foam structure may comprise controlling the relative levels of inclusion in the slurry of the foamable and non-foamable binders.
  • the cross-linking agent may be an agent which provides free calcium ions in aqueous solution, such as calcium sulphate, calcium citrate, calcium carbonate, calcium phosphate, calcium hydroxide, tobacco, or a tobacco-containing material.
  • the smokeable material may have a bulk density in the range of from about o.oig/cms to about i.5g/cm3, such as from about o.oig/cms to about o.ig/cms.
  • the filling value may be controlled by controlling, generally in combination with other variables, the overrun of the slurry.
  • the level of overrun may be controlled to be in the range of from about 20% to about 300%, such as from about 30% to about 150%.
  • the method of production of the smokeable material generally comprises a band-casting process, or may in the case of foamed materials comprise a freeze-drying process.
  • the aerosol generating means may be one or more of glycerol, propylene glycol, triethylene glycol, triethyl citrate, triacetin, sorbitol, or lactic acid, and may be present in the range of between about 5% to 50%, or preferably 10% to 35% by weight of the dry smokeable material.
  • binder is considered to refer to agents which may be included in the smokeable material to support and stabilise the material.
  • the binder may be cross-linkable.
  • the binder is cross-linked to provide support and stabilisation to the foam structure of the smokeable material.
  • the binder may or may not be cross-linked.
  • the binder may be an alginic binder, which may be a soluble alginate such as ammonium alginate, sodium alginate, sodium calcium alginate, calcium ammonium alginate, potassium alginate, magnesium alginate, triethanol-amine alginate.
  • the binder may be a foamable binder, which may be an esterifred alginate, such as propylene glycol alginate or other suitable chemically modified foaming alginates.
  • a non-foamable binder may be used in combination with a foaming agent.
  • the smokeable material is a sheet material, and generally the smokeable material does not contain tobacco or fibrous material such as cellulosic material.
  • a smokable material having a controlled filling value.
  • the smokeable material is a non-foamed smokeable material and comprises an alginic binder, glycerol, a first particulate inorganic filler material, and a second particulate inorganic filler material.
  • the first and second particulate inorganic filler materials have different bulk densities.
  • the filling value of the smokeable material may be controlled by controlling the relative levels of inclusion of the first and second inorganic filler materials.
  • the first particulate inorganic filler material may be expanded perlite or expanded vermiculite, and the second particulate inorganic filler material may be calcium carbonate.
  • the two inorganic filler materials may be included in the smokeable material in any relative proportion. For example, the relative levels of inclusion in the smokeable material of the two inorganic filler materials may be in the range of 1:100 to 100: 1 by weight.
  • a smokable material having a controlled filling value having a controlled filling value.
  • the smokeable material is obtainable by drying a stabilised foam having a controlled foam structure.
  • the foam is produced from a slurry comprising a foaming agent, aerosol generating means, and a binder, and the binder has been cross-linked with a cross-linking agent after aeration of the slurry.
  • the filling value of the foamed smokeable material is controlled to be in the range of about o.5cm3/g to about 20cm3/g.
  • the filling value is controlled to be in the range of about 3cm3/g to about I2cm3/g, such as about 5cm3/g to about iocm3/g, such as more than about 5.6cm3/g.
  • the smokeable material may further comprise a first particulate inorganic filler material and a second particulate inorganic filler material, wherein the first and second particulate inorganic filler materials have different bulk densities.
  • the filling value of the material may be further controlled by controlling the relative levels of inclusion of the first and second inorganic filler materials.
  • the level of overrun of the slurry may be controlled to be in the range of from about 20% to about 300%, such as from about 30% to about 150%.
  • a blend comprises tobacco blended with the smokeable material produced by the disclosed method.
  • a smoking article comprising the smokeable material produced by the disclosed method.
  • the smokeable material does not form part of the wrapper of the smoking article.
  • Figure ⁇ is a diagram illustrating a suitable method for measuring the filling value of a smokeable material
  • Figure 2 is a graph of filling value versus relative weight fraction of filler materials
  • Figure 3 is a graph of percentage overrun versus mechanical aeration time
  • Figure 4 is a graph of thickness of dry smokeable sheets versus percentage overrun.
  • Figure 5 is a graph of bulk density of dry smokeable sheets versus percentage overrun.
  • the filling value is frequently used in the field of smokeable materials to quantify the ability of a smokeable material to fill a smoking article such as a cigarette rod.
  • the filling value is the ability of a material to occupy a volume when compressed.
  • the skilled person will be aware of how to determine the filling value of smokeable materials.
  • the filling value is measured as volume per unit weight (cm 3 /g), however the filling value is not simply the inverse of density because it is also dependent upon the capacity of the material to resist compression.
  • a suitable method of measuring the filling value of a smokeable material involves the use of a Borgwaldt densimeter as illustrated in Figure 1. In accordance with this method, into a cylinder 1 of known dimensions, is inserted a sample of smokeable material of known mass 2.
  • the sample of smokeable material is then subjected to pressure from a ikg weight 3 for 30 seconds (Figure IC).
  • the filling value of the smokeable material is the volume occupied by the compressed sample divided by the mass of the sample. The measurement of filling value is discussed in more detail with reference to the specific Examples.
  • the filling value of smokeable materials produced by the disclosed method may be controlled to be in the range of about o.5cm 3 /g to about 20cm3/g.
  • the filling value may be controlled to be in the range of icm3/g to I2cm3/g, such as 2cm3/g to iocm3/g.
  • a method of controlling the filling value of a smokeable material may be mixed with tobacco to produce a blend for use in a smoking article.
  • the amount of tobacco-derived substances present in the smoke may be reduced.
  • a proportion of the tobacco in the blend is essentially replaced by the non- combustible inorganic filler.
  • a proportion of the tobacco in the blend is essentially replaced by the gas contained within the foam.
  • the filling value of previous smokeable materials was determined after the material had been manufactured. According to the present method, however, the filling value of the smokeable material may be controlled, and therefore the smokeable material maybe produced to a target filling value.
  • the filling value of the smokeable material may be controlled by controlling the relative levels of inclusion in the smokeable material of at least two inorganic filler materials having different bulk densities and/ or the foam structure of the smokeable material.
  • the foam structure of the smokeable material relates to the composition and physical properties of the foamed slurry.
  • the foam structure maybe controlled by controlling the amount and type of binder or binders present in the slurry.
  • the binder supports and stabilises the foam structure and hence the inclusion of a greater amount of binder in the slurry maybe expected to increase the strength and resistance to compression of the foam structure.
  • the binder may comprise a combination of different binders, such as (in the case of foamed smokeable materials) foamable and non-foamable binders.
  • the presence of a foamable binder may increase the capacity of the slurry to foam, increasing the volume of the foam structure.
  • the binder may be cross-linkable, and the use of a cross-linking agent to cross-link the binder may strengthen and support the foam structure. In this way, cross-linking the binder may increase the resistance of the foam structure to collapse as the slurry is dried. Cross-linking the binder may also increase the strength and resistance to compression of the foam structure. Finally, the slurry may be aerated to generate a foam. Increasing the degree of aeration, measured as the degree of overrun, may increase the volume of the foam structure.
  • the filling value of the smokeable material may be controlled by including in the slurry at least two inorganic filler materials having different bulk densities. Using an increased proportion of the low bulk density material may increase the filling value of the final smokeable material. Conversely, using an increased proportion of the high bulk density material may reduce the filling value of the final smokeable material.
  • the skilled person can produce a smokeable filler material to a target filling value.
  • the filling value may be controlled to provide a higher filling value than when the smokeable material is a non-foamed or substantially non-foamed material.
  • the filling value may be in the range of about 3cm3/g t 0 about I2cm3/ g, preferably from about 5cm3/ g to about locms/ g, such as more than about 5.6cm3/g.
  • the filling value may be in the range of about o.5cm3/g to about 7cm3/g, preferably from about i.5cm3/g to about 6cm3/g, such as less than about
  • the filling values of previous tobacco substitute materials comprising inorganic filler materials are generally lower than the filling values of conventional tobacco blends, and are typically about i.5cm3/g. Previous tobacco substitute materials comprising inorganic filler materials could not be used to substantially replace tobacco in smoking articles due to their low filling value.
  • the present method allows the production of smokeable materials comprising inorganic filler materials having controlled fill values substantially greater than was previously possible, which allows the possibility of using smokeable materials to replace tobacco in smoking articles.
  • a method of controlling the filling value of a smokeable material is provided, the method involving the following steps:
  • a binder which may be, or include, a foamable binder
  • inorganic filler material if required, which may be a combination of at least two inorganic filler materials having different bulk densities;
  • additives such as colourants, flavourants, and/or fibrous material, if required.
  • the disclosed methods of controlling the filling value of a smokeable material comprise producing the smokeable material from a slurry.
  • the slurry may be a slurry in the conventional sense, in that it comprises a suspension of solid particles (such as particulate filler material) in a liquid.
  • the "slurry" may simply be a liquid or a mixture which does not contain particulate material.
  • the method may involve the following steps:
  • additives such as organic agents, colourants, flavourants, and/or
  • the method may involve the following steps:
  • a binder which may be a foamable binder, or a combination of foamable and non-foamable binders
  • additives such as organic agents, colourants, flavourants, and/ or
  • a method of controlling the filling value of a smokeable material comprising the inclusion of inorganic filler material in the smokeable material.
  • the method comprising the inclusion of inorganic filler material in the smokeable material.
  • the effect on the filling value of the smokeable material may be controlled when the at least two inorganic filler materials used have different bulk densities.
  • using an increased proportion of the low bulk density material increases the filling value of the final smokeable material.
  • using an increased proportion of the high bulk density material reduces the filling value of the final smokeable material.
  • the at least two inorganic filler materials may be different materials, or may be different types of the same material, the different types of the same material having different bulk densities.
  • any non-combustible inorganic filler material may be suitable for use in the method of controlling the filling value of a smokeable material.
  • Inorganic filler materials which may be included in the smokeable material include expanded perlite, zeolite, alumina, vermiculite, expanded vermiculite diatomaceous earth, colloidal silica, calcium carbonate (chalk), magnesium oxide, magnesium sulphate, magnesium carbonate, zinc oxide, calcium sulphate (gypsum), ferric oxide, pumice, titanium dioxide, calcium aluminate, and other suitable inorganic filler materials will be known to the skilled person.
  • Inorganic filler materials which are particularly suitable for use as lower bulk density materials may include expanded perlite, diatomaceous earth, expanded vermiculite, and magnesium carbonate.
  • Inorganic filler materials which are particularly suitable for use as higher bulk density materials may include calcium carbonate, magnesium oxide, magnesium sulphate, zinc oxide, calcium sulphate, ferric oxide, and calcium aluminate.
  • a combination of chalk and expanded perlite, or chalk and expanded vermiculite may be used in the smokeable material.
  • the terms “higher bulk density” and “lower bulk density” are merely relative terms, and filler materials which have a relatively high bulk density may nevertheless be considered to be the "lower bulk density” filler material when used in a smokeable material in combination with an inorganic filler material having a higher bulk density.
  • the smokeable material comprises a plurality of inorganic filler materials with different bulk densities, and the filling value of the smokeable material may be controlled by controlling the relative levels of inclusion of the inorganic filler materials.
  • Inorganic filler materials which are suitable for use as lower bulk density materials generally have a bulk density in the range of from about o.oig/ cm 3 to about o.5g/cm 3 , or from about o.05g/cm 3 to about o.4g/cm 3 .
  • the bulk density may be below o.3g/cm 3 , o.25g/cm 3 , or o.2g/cm 3 .
  • the bulk density of the lower bulk density material maybe in the range of from about o.oig/cm 3 to about o.3g/cm 3 .
  • Inorganic filler materials which are suitable for use as higher bulk density materials generally have a bulk density in the range of from about o.2g/cm 3 to about io.og/cm 3 or from about o.3g/cm 3 to about 8g/cm 3 .
  • the bulk density maybe above o.4g/cm 3 , o.5g/cm 3 , or o.6g/cm 3 .
  • the bulk density of the higher bulk density material maybe in the range of from about o.6g/cm 3 to about 6.og/cm 3 .
  • the bulk density may depend on numerous factors including temperature, particle size and water content. Suitable methods for measuring the bulk density will be known to the skilled person.
  • the bulk densities of one, both, or all, of the inorganic filler materials may be outside of these ranges, the principle is that a plurality of filler materials may be used in the smokeable material, the different filler materials having different bulk densities.
  • a method of controlling the filling value of a smokeable material comprising the inclusion of at least two inorganic filler materials in the smokeable material.
  • the first and second particulate inorganic filler materials may be present in any relative proportions.
  • the inorganic filler materials maybe present in the approximate relative proportions of i:ioo to 100:1, 1:50 to 50:1, 1:20 to 20:1, 1:10 to 10:1, 1:5 to 5:1, 1:4 to 4:1, 1:3 to 3:1, 3:8 to 8:3, 3:7 to 7:3, 1:2 to 2:1, 3:5 to 5:3, 3:4 to 4:3, or 1:1.
  • the preferred ratio will depend on a number of factors including the particular inorganic filler materials used and the desired filling value of the final smokeable material.
  • Smokeable materials having a foamed or substantially foamed structure may comprise no inorganic filler or only very small level inclusions of one or more inorganic fillers.
  • the method may comprise the inclusion of three or more inorganic filler materials having different bulk densities.
  • four, five, or six, inorganic filler materials maybe used in the smokeable material.
  • the mean particle size of the total amount of inorganic filler material used in the smokeable material may be in the range of from about ⁇ to about 3 ⁇ , from about 55 ⁇ to about 5 ⁇ , from about 5 ⁇ to about ⁇ 5 ⁇ , and is generally greater than ⁇ 25 ⁇ or ⁇ 50 ⁇ , such as at or about ⁇ 7 ⁇ .
  • the smokeable material is a foamed or substantially foamed smokeable material having a controlled filling value
  • filler material having a much smaller particle size than this may be used because having a small particle size may be advantageous due to the foamed structure of the material and the fact that a significant proportion of the material comprises bubbles of gas.
  • the mean particle size of the total amount of inorganic filler material used in the smokeable material may be in the range of from about 0.5 ⁇ to about 3 ⁇ , from about 0.8 ⁇ to about 2 ⁇ , from about ⁇ to about ⁇ , and maybe less than 3 ⁇ or 2 ⁇ , such as at or about ⁇ .
  • the inorganic filler materials may have substantially different mean particle sizes.
  • one filler material maybe of a smaller mean particle size while the other filler material may be of a larger mean particle size.
  • the inorganic filler material is generally a particulate material and is suitably not in agglomerated form. The inorganic filler material should require little pre- treatment, other than perhaps size gradation, before use.
  • a method of controlling the filling value of a smokeable material comprising obtaining particulate inorganic filler material of the desired particle size.
  • the inorganic filler material may be ground, milled or precipitated to the desired particle size.
  • Particles of the desired size may be obtained by sieving or by means of any other form of particle classification.
  • the particles of inorganic filler material may have any shape.
  • the particles may be substantially spherical, cubic, or the particles may have a dendritic morphology.
  • a method of controlling the filling value of a smokeable material wherein the total amount of inorganic filler material present in the smokeable material, that is the total amount of the at least two inorganic filler materials, may be in the range of from 0% to about 90% by weight of the dried smokeable material.
  • the total amount of inorganic filler material present in smokeable materials which have a non-foamed, or only very slightly foamed structure may be in the range of 10% to 90%, or 20% to 85%, such as 30% to 80%.
  • the total amount of inorganic filler material present is greater than about 50%, 55%, 60%, or 65%, and is preferably greater than 70%, such as, for example, 72%, 74%, or 76%.
  • a method of controlling the filling value of a smokeable material which is a foamed smokeable material comprising inorganic filler.
  • the inorganic filler may be a combination of different filler materials, or a single inorganic filler material.
  • inorganic filler material may be present in the range of about 0% to about 80%, such as from about 5% to about 50%, from about 10% to about 40%, and is generally present from about 5% to about 20% by weight of the dry smokable material.
  • the particle size of the inorganic filler material may also influence the static burn rate of a smoking material comprising the smokeable material produced by the disclosed method.
  • the smoke taste and flavour characteristics and the physical characteristics of a smoking article incorporating the smokeable material may also be controlled in this way.
  • a method of controlling the filling value of a smokeable material comprising controlling the foam structure of the smokeable material.
  • the foam structure may comprise an aerated cellular structure resembling a mass of densely packed, fine bubbles. Many features of the foam structure may be manipulated, including the specific ingredients and the amounts used, the bubble size and density, and the thickness, strength and elasticity of the bubble wall.
  • the filling value of the smokeable material may be controlled by controlling the foam structure, wherein controlling the foam structure may comprise controlling the amount and composition of the binder in the slurry, the degree of aeration of the slurry, and/ or the extent to which the binder is cross-linked.
  • the smokeable material having a foamed or substantially foamed structure may be formed by creating bubbles of gas, such as a thick froth, in the initial liquid or slurry solution to form a wet foam, and then drying the material to solidify it and preserve the fine structure of the bubbles.
  • gas such as a thick froth
  • the problem commonly experienced in connection with prior art foamed smokeable materials is that, during their manufacture, the wet foam collapses as it is dried. A collapsed foam has a reduced filling power, which cannot be reliably and predictably controlled.
  • the present method relates to the production of a stabilised foam that can be dried without collapsing, to form a smokeable material having a controllable filling value.
  • the smokeable material thus retains the foamed structure and therefore the filling properties of the resultant dried foam can be predicted and controlled.
  • the composition of the initial slurry and the degree of aeration of the wet foam, for example, can be controlled, and these properties may be translated to the final smokeable material because the structure of the foam does not inconsistently collapse or otherwise change as the material is dried.
  • the degree of aeration is the amount of air entrained in the foamed material and may be determined indirectly by calculating the "overrun".
  • the overrun may be calculated by measuring the difference in mass of a given volume of the wet slurry before and after aeration, and is used as a measure of the degree of aeration.
  • the level of overrun may be in the range of from about 20% to about 300%, or from about 25% to about 250% such as from about 30% to about 150%.
  • the level of overrun of the slurry may be greater than 70%, 80%, 90%, or 100%.
  • a method of controlling the filling value of a smokeable material comprising controlling the foam structure of the smokeable material.
  • a foaming agent may be used in the initial liquid or slurry solution, and this initial solution is then aerated to produce the foamed structure of the smokeable material.
  • the initial solution also contains a cross-linkable binder which can be chemically cross-linked using a cross- linking agent to form a matrix. Collapse of the wet foam is thus prevented by cross- linking the binder, thereby preserving the foam structure. Cross-linking of the binder in this way stabilizes and supports the foam and thus preserves and maintains the delicate structure of the foam as the smokeable material is dried.
  • Smokeable materials having a foamed or substantially foamed structure which are prepared without cross-linking do not form a stabilised foam, and tend to collapse on drying, and therefore do not have a structure with a controllable filling value.
  • stabilizing the material by cross-linking the binder preserves the foam structure and gives predictability to the final structure of the smokeable material and therefore controllability to the filling value.
  • a method of controlling the filling value of a smokeable material comprising the use of a foaming agent.
  • the function of the foaming agent and binder are provided by a single agent, which is referred to as a foamable binder.
  • a separate foaming agent and non-foamable binder may be used.
  • foaming of the foaming agent may be provided by the application of a mechanical force or, alternatively, may be facilitated by the passing of a gas through the foaming agent.
  • the gas may be air or may be another gas, such as nitrogen, helium, argon, or neon, for example.
  • Foaming of the foaming agent may also be facilitated under conditions of pressure other than ambient. Foaming may be facilitated in vaccuo or under elevated pressure. Foaming may additionally or alternatively result from a chemical reaction, the reaction resulting in the production of a gas such as carbon dioxide, or nitrogen for example.
  • Suitable chemical reactions may be inorganic, such as the reaction of an acid and base, or may be biological in nature, such as a fermentation process.
  • foaming of the initial liquid or slurry solution is achieved by means of direct injection of air.
  • the precise degree of aeration may be controlled by controlling the air flow to give a foamed material having a specific target density.
  • Another preferred method of aerating the material is by entraining air into the initial liquid or slurry solution using a mixer.
  • the degree of aeration can be controlled by adjusting the parameters of the mixing process such as the mixing time, mixing speed, etc.
  • increased aeration time may correlate with increased thickness, decreased grammage, and decreased density of the smoking material, and this can be controlled, generally with other parameters, to control the filling value of the smokeable material.
  • Aeration may be facilitated by specialist mechanical high shear aeration machinery known to those skilled in the art.
  • Aeration may be effected via pumping through a high shear mixing and aeration system, or utilising a static high shear mixing system.
  • the aeration time may be in the range of from about 10 seconds to about 30 minutes.
  • the aeration time may be in the range of about 15 seconds to about 20 minutes, from about 20 seconds to about 15 minutes, from about 25 seconds to about 10 minutes, from about 30 seconds to about 7 minutes, or from about 1 minute to about 5 minutes, such as about 2 minutes.
  • any suitable foaming agent may be used, and the foaming agent may be a foaming surfactant.
  • the foaming agent maybe, for example: a cellulose capable of foaming, such as hydroxypropyl cellulose, methyl cellulose or ethyl cellulose; starch; modified starch; proteins, such as egg albumin; sugar esters; or a foaming alginate, which maybe an esterified alginate, such as propylene glycol alginate.
  • suitable foaming agents will be known to the skilled person.
  • the foaming agent may be a foamable binder. Generally, the foaming agent is hydroxypropyl cellulose (HPC).
  • the method comprises the use of separate foaming agent and binder, and in this case, the foaming agent may be present in the range of from about 0% to about 70%, from about 0.5% to about 40%, from about 2% to about 35%, or from about 2% to about 30% by weight of the dry smokeable material.
  • the foamable binder may be present in the range of from about 5% to about 90%, preferably about 10% to about 80% by weight of the dry smokeable material.
  • a method of controlling the filling value of a smokeable material wherein the smokeable material is a self-supporting foam when dried.
  • the cross-linked foamed material may be chemically stabilised without the need for a specific drying process.
  • drying of the stabilised foamed material generally further stabilises the foamed structure and enables the smokeable material to be further processed, if required. Therefore, in order to maintain
  • the foamed material may be dried.
  • the moisture content of the dried smokeable material may be in the range of from 0% to about 30%, such as from about 1% to about 20%. Generally, when the smokeable material is a non-foamed or substantially non-foamed smokeable material, the moisture content of the dried smokeable material may be may be lower than when the smokeable material is a foamed or substantially foamed material.
  • the moisture content of materials having a non-foamed or substantially non-foamed structure may be in the range of from about 1.5% to about 10%.
  • the moisture content of materials having a foamed or substantially foamed structure may be in the range of from about 3% to about 10%.
  • the moisture content of tobacco-containing sheets is generally in the range of about 12% to about 15% such as about 13.5%. Binder
  • binder refers to agents which are included in the smokeable material to support and stabilise the material.
  • a method of controlling the filling value of a smokeable material wherein the smokeable material is produced from a slurry comprising a binder.
  • the binder may function to hold the material together and as a result, to improve the physical properties of the dried smokeable material.
  • the binder maybe cross-linkable, that is, it maybe capable of forming chemical cross-linkages to produce a matrix, and thereby strengthen and support the material. Cross-linking the binder to produce a matrix in this way may be particularly useful when the smokeable material is a foamed or substantially foamed smokeable material and the method of controlling the filling value of the smokeable material comprises controlling the foam structure of the smokeable material.
  • cross-linking the binder allows the fine structure of the foam to be maintained as the material is dried, and as a result the filling value of the final smokeable material can be predictably and consistently controlled by controlling the degree of foaming and aeration of the wet foam, generally in conjunction with other variables as discussed above.
  • cross-linking the binder may improve the control of the filling value of the smokeable material.
  • the binder may be an organic binder such as an alginic binder. Alginates are suitable for use in the smokeable material due to having a neutral taste character upon combustion. Alginates also have advantageous burning properties.
  • Suitable alginic binders include soluble alginates, such as ammonium alginate, sodium alginate, sodium calcium alginate, calcium ammonium alginate, potassium alginate, magnesium alginate, triethanol-amine alginate and propylene glycol alginate, or insoluble alginates which can be rendered soluble by the addition of solubilising agents, such as ammonium hydroxide. Examples of these include aluminium, copper, zinc and silver alginates.
  • binders include cellulosic materials, gums or gels.
  • Suitable cellulosic materials include cellulose and cellulose derivatives, such as sodium carboxymethylcellulose, methyl cellulose, hydroxypropyl cellulose,
  • hydroxyethyl cellulose or cellulose ethers examples include gum arabic, gum ghatti, gum tragacanth, Karaya, locust bean, acacia, guar, quince seed or xanthan gums.
  • Suitable gels include agar, agarose, carrageenans, furoidan and furcellaran. Pectins and pectinaceous materials may also be used, and also starches and modified starches.
  • alginic and non-alginic binders may be used.
  • a binder or a combination of binders may be used that can interact with solublised calcium ions to form a cross-linked structure.
  • Cross-linking the binder in this way may strengthen and support the smokeable material. Added strength maybe beneficial to provide the smokeable material with improved processing capability, for example, during a blending procedure with tobacco or other materials.
  • binders that may be cross-linked include alginates, which maybe cross-linked with calcium ions in particular, and pectins, which may be cross-linked using calcium or magnesium ions.
  • binders that are incapable of being cross-linked with dissolved ions maybe used.
  • binders include guar gum.
  • the binder maybe capable of both forming chemical cross-linkages, and acting as a foaming agent, and such a material is described as a "foamable binder".
  • the binder may not be capable of acting as a foaming agent, in other words, it may be a "non-foamable binder".
  • Foamable binders are chemically cross-linkable materials that also have the property of being a foaming agent, for example, a foamable binder may have surfactant properties and thereby facilitate the formation of a foam.
  • a surfactant is usually amphiphilic, containing both hydrophobic and hydrophilic groups.
  • Suitable foamable binders include propylene glycol alginate, which is made by esterifying a portion of the carboxylate groups of a soluble salt of alginic acid with propylene glycol, and is a foamable binder due to the presence of the hydrophobic propylene glycol ester groups.
  • binders such as metal salts of alginic acid, including sodium alginate and potassium alginate, which lack such hydrophobic groups, are not amphiphilic and therefore cannot be considered foamable binders.
  • a foamable binder may be used in the range of from about 5% to about 90%, such as from about 10% to about 80% by weight of the dry smokeable material.
  • Foamable binders may also be used in the non-foamed state.
  • a foamable binder may nevertheless be used as a binder in its non-foamed state.
  • a method of controlling the filling value of a smokeable material wherein the filling value is predominantly controlled by controlling the relative levels of inclusion of at least two inorganic filler materials having different densities, and wherein the smokeable material has a non-foamed or substantially non-foamed structure.
  • the total amount of binder present may be less than about 60% by weight of the dry smokeable material, such as from about 1% to about 45% by weight, about 1% to about 35% by weight, from about 3% to about 30% by weight, or from about 5% to about 25% by weight.
  • the binder is generally a non-foamable alginate binder.
  • a method of controlling the filling value of a smokeable material wherein the smokeable material has a foamed or substantially foamed structure and the method comprises controlling the foam structure of the smokeable material.
  • the binder maybe a foamable binder, or alternatively, a non-foamable binder may be used in combination with a separate foaming agent. Generally, the amount of binder used is reduced when a separate binder and foaming agent are used versus when a foamable binder is used.
  • the amount of binder may be in the range of about 3% to about 70%, about 6% to about 60%, about 11% to about 50%, and is preferably about 21% to about 40%.
  • the foamable binder may be used in the amount of about 5% to about 90%, and is preferably about 10% to about 80%.
  • the binder used may comprise a combination of foamable and non-foamable binders.
  • a method of controlling the filling value of a smokeable material comprising the use of a binder and a cross-linking agent to chemically cross-link the binder and thereby strengthen and support the smokeable material.
  • the use of a cross-linking agent to cross-link the binder may, in particular, be required when the smokeable material has a foamed structure. In this case, it may be necessary to use a cross-linking agent to ensure that collapse of the foam structure is minimised as the material is dried, so that the filling power of the material is maintained and is therefore controllable.
  • a cross-linking agent may also be used in connection with smokeable materials having non-foamed or substantially non-foamed structures to control the quality of the sheet if necessary.
  • the cross-linking agent releases calcium or other divalent metal ions, which make up the cross-links in the resultant smokeable material.
  • the counterions such as sulphate anions
  • the final smokeable material may therefore not necessarily contain a cross-linking agent, only cross-linked binder.
  • a method of controlling the filling value of a smokeable material involves the use as a cross-linking agent of a source of free calcium ions.
  • Any source of free calcium ions may be utilised as a cross-linking agent.
  • the cross-linking agent may be an agent which provides free calcium ions in aqueous solution.
  • the cross-linking agent may be a calcium salt which is soluble or sparingly soluble at neutral pH (pH 7.0), such as calcium sulphate, or calcium citrate.
  • the cross-linking agent maybe a calcium salt which is insoluble at neutral pH, but becomes soluble or sparingly soluble at acidic pH, such as calcium carbonate or calcium phosphate, for example.
  • the cross-linking agent may be a calcium salt which is soluble or sparingly soluble, and forms an alkaline solution, such as calcium hydroxide, for example.
  • the filler material may contribute divalent metals ions such as calcium ions which may cross-link the binder.
  • the cross-linking agent may be tobacco or a tobacco-containing material.
  • the tobacco provides free calcium ions in the presence of water. It will be known to the skilled person that different types of tobacco provide different concentrations of free calcium ions in solution, and therefore the tobacco should be present in an amount capable of cross-linking the binder.
  • the tobacco For use as a cross-linking agent, it is generally preferred for the tobacco to have a small particle size, for example less than 25 ⁇ , although tobacco particles of various sizes may be used.
  • the smokable filler material may comprise, as a cross- linking agent, both tobacco and a further agent capable of providing free calcium ions.
  • the cross-linking agent may alternatively be an agent which provides multivalent or divalent cations, other than calcium, in solution. Suitable agents will be known to the skilled artisan.
  • the method comprises including a cross-linking agent in the smokeable material.
  • the amount of cross-linking agent required depends on a number of factors, including the extent to which the smokeable material is foamed, the nature of the cross-linking agent, the nature of the binder, and the nature of the foaming agent used.
  • a cross-linking agent is generally used when the smokeable material has a foamed structure.
  • the cross-linking agent may be used to control the foam structure since the more complete is the cross-linking of the binder, the greater is the resistance of the foam to collapse as it is dried.
  • a cross-linking agent may also be used in the production of smokeable materials having non-foamed or substantially non-foamed structures, and in this case, cross- linking may increase the tensile strength of the smokeable material.
  • the smokeable material comprises a foamable binder and the cross- linking agent is a calcium salt, or a combination of tobacco and a calcium salt
  • the calcium salt may be present in the range of from about 1.0% to about 50% or from about 2% to about 30%, such as between about 20% and about 25%, by weight of the dry smokable filler material.
  • the tobacco material may be present in the range of from about 10% to about 80%, or at about 20% by weight of the dry smokeable material.
  • the cross-linking agent may be present in the range of from about 0.2% to about 50% or from about 0.5% to about 25% by weight of the dry smokable filler material.
  • the non-foamable binder may be present in the range of from about 3% to about 70%, from about 3% to about 60%, or from about 3% to about 40% by weight of the dry smokeable material.
  • the foaming agent may be present in the range of from about 0.5% to about 70%, from about 3% to about 30%, or from about 20% to about 25% by weight of the dry smokeable material.
  • the smokeable material comprises a non-foamable binder and the cross- linking agent is a combination of tobacco and a calcium salt
  • the calcium salt may be present in the range of from about 0.5% to about 10%, or from about 2% to about 4% by weight of the dry smokable filler material.
  • the tobacco may be present in the range of from about 10% to about 80% or at about 20% by weight of the dry smokable filler material.
  • the non-foamable binder may be present in the range of from about 3% to about 55%, or from about 11% to about 30% by weight of the dry smokeable material.
  • the foaming agent may be present in the range of from about 2% to about 30%, or from about 11% to about 25% by weight of the dry smokeable material.
  • the tobacco may be present in the range of from about 10% to about 80% or at about 20% by weight of the dry smokable filler material.
  • the non-foamable binder may be present in the range of from about 6% to about 60%, from about 11% to about 50%, from about 21% to about 40%, or from about 31% to about 40% by weight of the dry smokeable material.
  • the foaming agent may be present in the range of from about 3% to about 30%, or from about 20% to about 25% by weight of the dry smokeable material.
  • the cross-linking agent is present in an amount, or of a solubility, insufficient to induce syneresis of the stabilised foamed material. Syneresis occurs when the level of cross-linking agent is too great and the stabilised foam material begins to collapse due to the strength of the cross-linkages therein.
  • the method comprises including aerosol generating means in the smokeable material.
  • the aerosol generating means may comprise aerosol forming means, such as polyhydric alcohols, such as glycerol, propylene glycol or triethylene glycol; esters such as triethyl citrate or triacetin; high boiling point hydrocarbons; or non-polyols, such as glycols, sorbitol or lactic acid, for example. Combinations of the aerosol forming means may also be used. Generally, glycerol is used as the aerosol generating means.
  • An additional function of the aerosol generating means may be the plasticising of the sheet material.
  • Suitable additional plasticisers include water.
  • the aerosol generating means may be present in the amount of up to about 65% by weight of the dry smokeable material. Generally, the aerosol generating means may be present in the range of from about 1% to about 60%, from about 5% to about 50%, or from about 10% to about 35% by weight of the dry smokeable material.
  • At least a proportion of the aerosol generating means may be encapsulated, preferably micro-encapsulated, or stabilised in some other way. In such cases the amount of aerosol generating means may be higher than the range given.
  • the smokeable material may act as both a tobacco substitute, which may be used to partially replace tobacco, and also as a mainstream smoke diluent.
  • the use of the smokeable material can influence the yields of mainstream smoke constituents.
  • flavourant refers to materials which, where local regulations permit, may be used to create a desired taste or aroma in a product for adult consumers.
  • the method comprises including a colourant and/or a flavourant in the smokeable material.
  • the colourant maybe used to darken the material and the flavourant maybe used to impart a particular flavour.
  • Finely ground, granulated or homogenised tobacco may also be used.
  • Industry approved food colourants may also be used, such as Eisoa (caramel), E151 (brilliant black BN), E153 vegetable carbon or E155 (brown HT).
  • Suitable flavourants include menthol and vanillin, for example.
  • a colourant or flavourant may be present in the smokeable material in an amount of up to about 10%, and are generally present in the range of from about 5% to about 7% of the final smokeable material.
  • Colourant may be present in an amount of up to about 5%, or up to about 4%, and in particular, in an amount of about 2%, by weight of the final smoking material.
  • Food dyes maybe present in the amount of at least about 0.5% by weight of the final smokeable material.
  • Other suitable colourants include molasses, malt extract, coffee extract, tea resinoids, St. John's Bread, prune extract or tobacco extract. Mixtures of colourants may also be used.
  • colourants and/or flavourants are generally added to the slurry during the manufacture of the smokeable material and are therefore incorporated into the structure of the material, rather than applied to the surface. However colourants and/ or flavourants may also be applied to the surface of the final smokeable material.
  • the method comprises including additional fibrous material in the smokeable material.
  • tobacco may be included in the smokeable material.
  • the tobacco may be present as a cross-linking agent or, alternatively, may be present in addition to a non-tobacco cross-linking agent.
  • the tobacco may be lamina, stem, fines, dust, reconstituted tobacco or other tobacco material.
  • the method comprises including, in addition to, or as an alternative to any tobacco, a further fibrous material in order to provide the smokeable material with one or more of higher strength, lower density or higher filling value.
  • the further fibrous material may be, for example, one or a combination of wood pulp, flax, bast, or cellulosic material. It will be understood by the skilled person that the foamable or non-foamable binder is not considered a further fibrous material.
  • the further fibrous material may be present in the range of from about 0.5% to about 15%, from about 1% to about 7%, from about 2% to about 5%, or at about 3% by weight of the dry smokable filler material.
  • the smokeable material does not contain tobacco, and there is preferably no fibrous material present in the smokeable material, cellulosic or otherwise.
  • the method comprises including a carbonaceous material in the smokeable material.
  • Carbonaceous materials that maybe used in the smokeable material include carbon, and activated carbon in any suitable form.
  • the term "carbonaceous” includes material which has been pyrolysed, which material preferably contains carbon, although some incomplete combustion products may still be present.
  • the carbonaceous material maybe present in the dry smokeable material in the range of from about 0.1% to about 10% by weight. In other words,
  • the smokeable materials do not comprise carbon material such as activated carbon material.
  • the smokeable materials do not comprise a clay material such as a material comprising smectite or bentonite.
  • Smokeable material produced by the disclosed method generally has sufficient strength and is of an acceptable density to undergo the rigours of normal sheet processing.
  • the strength of the material may be adjusted by controlling the degree of cross-linking of the foamable or non-foamable binder present in the material, in other words, by varying the amount of cross-linking agent that is added to the sheet slurry.
  • the method comprises producing the smokeable material in the form of a sheet.
  • the sheet may be an extruded sheet, or may be cast, for example using a heated drum caster or band casting equipment.
  • the method of production of the smokeable material comprises a band-casting process.
  • the sheet may be shredded or cut before incorporation into a smoking article.
  • the smokeable filler material may be incorporated into a smoking article as strips or the material may be rolled before being enwrapped in a wrapper.
  • the smokeable material Prior to blending with tobacco, the smokeable material is shredded at an appropriate cut width, which maybe in the range of 20 to 40 cuts per inch (cpi), such as 24cpi or 28 to 37cpi, although this may be varied according to purpose, as those skilled in the art would be aware.
  • cpi cuts per inch
  • a method of controlling the filling value of a smokeable material comprising controlling the foam structure of an aerated smokeable material, and in these embodiments, the bulk density of the smokeable material may be in the range of from about o.oig/cms to about lg/cms, such as from about o.oig/cms to about o.ig/cms.
  • the smokeable material produced in accordance with the method may be blended with tobacco or other smokeable material to form a blend. It will be understood by the skilled artisan that references to a "blend" may encompass materials comprising tobacco and/or tobacco substitute materials.
  • the smokeable material maybe blended with tobacco material to provide smoking material.
  • the tobacco material maybe any known tobacco material.
  • the smokeable material and tobacco may be incorporated into the blend in the amount of 5 to 80%, 10 to 60%, and is preferably incorporated in the amount of about 20% to 50%.
  • the smokeable material produced by the method may be used in a smoking article comprising a rod of smoking material enwrapped in a wrapper, the smoking material comprising a blend, which blend incorporates the smokeable material produced by the disclosed method.
  • the wrapper enwrapping the smoking article does not comprise the smokeable material.
  • the wrapper enwrapping the smoking article may comprise a burn additive, such as sodium and/or potassium citrate, for example.
  • Other suitable burn additives such as sodium or potassium salts, such as acetate and tartrate; mono-ammonium phosphate, and di-sodium hydrogen phosphate, for example, will be known to the skilled person.
  • the burn additive may be present in the range of about 0.5% to about 2.5% by weight of the wrapper.
  • the wrapper may also have a basis weight in the range of about 20g/m 2 to about 40g/m 2 .
  • a basis weight in the range of about 20g/m 2 to about 40g/m 2 .
  • Example 1 Controlling the filling value of a smokeable material by controlling the relative levels of inclusion in the smokeable material of two inorganic filler materials having different bulk densities.
  • Sodium alginate (binder) was hydrated using deionised water with intermittent mixing in a high shear mixer. The speed was then increased until the alginate was completely hydrated, forming a lump-free viscous liquid with no remaining undissolved alginate. Glycerol and colourant were subsequently added followed by the first inorganic filler (chalk) with continuous mixing. The second inorganic filler (perlite) was added with further continuous mixing until a smooth, flowing slurry was obtained. The slurry was cast onto metal casting plates using a casting knife, with a casting thickness of imm. The plates were then placed in a fan oven, which had been preheated to ioo°C, to dry the material.
  • the dried material adhering to the metal plate was placed facing into a steamy atmosphere to allow the sheet to sorb moisture.
  • the sheet was then 'doctored' off the metal plate utilising a sharp knife when the sheet had sorbed sufficient moisture to be removed intact as a coherent sheet from the metal casting plate.
  • the sheet material was conditioned at 22°C and 60% relative humidity for 48 hours before shredding at 37 cuts per inch utilising pilot scale shredding equipment.
  • Sample sheets of smokeable material were prepared in accordance with the formulations shown in Table 1.
  • Table 1 Formulations of smokeable material with different ratios of higher and lower bulk density inorganic filler materials.
  • Filler Material Percentage Weight Fraction is the percentage weight fraction of each inorganic filler material in the sheet formulation, and is calculated as follows:
  • WF LDF (%) (LDF x 100) / (LDF + HDF)
  • WF HDF (%) (HDF x 100) / (LDF + HDF)
  • the filling values of the samples of smokeable material were measured using a Borgwaldt Densimeter DD-60A.
  • FIG. 1 The method of determining the filling value is shown in Figure 1.
  • a cylindrical vessel 1 with an internal radius of 3cm was filled with shredded smokeable material 2.
  • a piston 3 weighing lkg was lowered onto the sample as shown in Figure i(b).
  • Example 2 Controlling the thickness and density of a foamed smokeable material by controlling the degree of aeration of the smokeable material.
  • Sodium alginate (binder) was hydrated using deionised water with intermittent mixing in a high shear mixer. The speed was then increased until the alginate was completely hydrated, forming a lump-free viscous liquid with no remaining undissolved alginate. Both pre-dissolved glycerol and pre-dissolved colourant were added with mixing.
  • Powdered foaming agent (hydroxypropyl cellulose) was then added, but with only a minimal degree of mixing, to ensure hydration with minimal air entrapment so that an accurate, first pre-aeration overrun measurement could be taken.
  • the slurry was then aerated to create a high volume mousse.
  • the mixture was aerated for 2, 5, 7 or 10 minutes as appropriate by mixing at maximum speed of the high shear mixer. After the slurry was aerated for the specified time period, the second (post-aeration) overrun measurement was recorded, again using a 200ml sample.
  • the foam structure was "fixed” using a cross-linker (calcium citrate) to stabilise the structure of the foam to drying.
  • Calcium citrate was added by mixing vigorously with the foam for 15 seconds.
  • the foamed slurry was cast onto metal plates using a casting knife, with a casting thickness of 3mm.
  • the plates were then placed in a fan oven, which had been preheated to ioo°C, to dry the material.
  • the sheet was then 'doctored' off the metal plate utilising a sharp knife.
  • a sample of the pre-aerated slurry was transferred from the mixer to a 200ml flat bottomed bowl.
  • the bowl was filled above the rim and then, using a horizontal spatula, the "head" was removed to ensure that the same volume of pre aerated sample was placed in the bowl was consistent between samples.
  • the mass of the pre-aerated sample was then determined. The procedure was repeated for the post aeration sample using the same 200ml flat bottomed bowl.
  • samples of smokeable material having dimensions of 15mm x 50mm were produced.
  • a Mitotoyu profile projector was used to measure the thickness of the samples of smokeable material with measurements taken at multiple points across the sample. The mean thickness of each sample of smokeable material (in mm) was then calculated.
  • Bulk density is the weight per unit volume of a non-uniform solid.
  • the density of the solid bubble walls and the amount of gas entrapped within the foam bubbles both contribute to the bulk density of the material.
  • the average bulk density was calculated using the sample thickness measurements and the dimensions of each sample of smokeable material, which in this case were 15mm x 50mm (giving a surface area of 750mm 2 ).
  • the bulk density was calculated according to the following formula:
  • Table 5 Percentage overrun versus mean thickness of test samples of smokeable material
  • Figure 4 illustrates the relationship between thickness and overrun of the foamed slurry for individual sheet repeat formulation samples.
  • Figure 5 illustrates the relationship between bulk density and overrun of the foamed slurry for individual sheet repeat formulation samples. There is a statistically significant difference between the mean bulk densities of the smokeable materials having different aeration times. This may be explained by the increasing ratio of air to solid content per unit volume of wet slurry, since the longer the aeration time the larger the inclusion of air into the wet foamed slurry as shown in Table 4.

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Abstract

L'invention concerne un procédé pour contrôler la valeur de remplissage d'une matière à fumer. Le procédé consiste à contrôler les niveaux relatifs d'inclusion dans la suspension épaisse d'au moins deux matières de charge inorganiques ayant des densités apparentes différentes et/ou à contrôler la structure de mousse de la matière à fumer.
PCT/GB2013/053132 2012-11-28 2013-11-27 Contrôle d'une matière à fumer WO2014083333A1 (fr)

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GB201221376A GB201221376D0 (en) 2012-11-28 2012-11-28 Controlling a smokeable material
GB1221376.5 2012-11-28

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WO2014083333A1 true WO2014083333A1 (fr) 2014-06-05

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WO2018122375A1 (fr) * 2016-12-29 2018-07-05 Jt International S.A. Mousse de tabac
WO2020002607A1 (fr) 2018-06-28 2020-01-02 Jt International S.A. Procédé de production de mousse de tabac
WO2021105465A1 (fr) * 2019-11-29 2021-06-03 Nicoventures Trading Limited Matériau générateur d'aérosol comprenant un solide amorphe comprenant du menthol et de l'alginate réticulé par du calcium
WO2021152087A1 (fr) * 2020-01-30 2021-08-05 Nicoventures Trading Limited Génération d'aérosol
US11206872B2 (en) 2020-04-07 2021-12-28 Consumernext Labs Gmbh Stable-foam dispensing device and cartridge
WO2022053982A1 (fr) * 2020-09-11 2022-03-17 Nicoventures Trading Limited Substrats à base d'alginate
CN115666277A (zh) * 2020-01-30 2023-01-31 尼科创业贸易有限公司 气溶胶发生材料
WO2023118211A1 (fr) * 2021-12-20 2023-06-29 British American Tobacco (Investments) Limited Matériau de génération d'aérosol comprenant un ou plusieurs agents de formation de mousse
WO2023242822A1 (fr) * 2022-06-17 2023-12-21 Nicoventures Trading Limited Feuille revêtue de tabac et consommable fabriqué à partir de celle-ci
US11980219B2 (en) 2018-04-06 2024-05-14 Philip Morris Products S.A. Nicotine gel

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US11412774B2 (en) 2016-12-29 2022-08-16 Jt International S.A. Tobacco mousse
CN110121272A (zh) * 2016-12-29 2019-08-13 Jt国际股份公司 烟草摩丝
EA039093B1 (ru) * 2016-12-29 2021-12-02 Джт Интернэшнл С.А. Табачный мусс
WO2018122375A1 (fr) * 2016-12-29 2018-07-05 Jt International S.A. Mousse de tabac
US11980219B2 (en) 2018-04-06 2024-05-14 Philip Morris Products S.A. Nicotine gel
WO2020002607A1 (fr) 2018-06-28 2020-01-02 Jt International S.A. Procédé de production de mousse de tabac
CN112334021A (zh) * 2018-06-28 2021-02-05 Jt国际股份公司 生产烟草摩丝的方法
WO2021105465A1 (fr) * 2019-11-29 2021-06-03 Nicoventures Trading Limited Matériau générateur d'aérosol comprenant un solide amorphe comprenant du menthol et de l'alginate réticulé par du calcium
CN115243569A (zh) * 2019-11-29 2022-10-25 尼科创业贸易有限公司 包含含有薄荷醇和钙交联的藻酸盐的非晶固体的气溶胶生成材料
CN115666277A (zh) * 2020-01-30 2023-01-31 尼科创业贸易有限公司 气溶胶发生材料
CN115023152A (zh) * 2020-01-30 2022-09-06 尼科创业贸易有限公司 气溶胶生成
WO2021152087A1 (fr) * 2020-01-30 2021-08-05 Nicoventures Trading Limited Génération d'aérosol
US11206872B2 (en) 2020-04-07 2021-12-28 Consumernext Labs Gmbh Stable-foam dispensing device and cartridge
WO2022053982A1 (fr) * 2020-09-11 2022-03-17 Nicoventures Trading Limited Substrats à base d'alginate
WO2023118211A1 (fr) * 2021-12-20 2023-06-29 British American Tobacco (Investments) Limited Matériau de génération d'aérosol comprenant un ou plusieurs agents de formation de mousse
WO2023242822A1 (fr) * 2022-06-17 2023-12-21 Nicoventures Trading Limited Feuille revêtue de tabac et consommable fabriqué à partir de celle-ci

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